OPERATORS MANUAL

Manual No: 901-10009

Model ID: AE-LP230V1V3
Revision Date: 12/12/2013

Low Temperature
All-Electric Cold Plate System

FLEET NUMBER ________________________________________

SERIAL NUMBER________________________________________
INSPECTED BY _________________________________________

ATTENTION This manual contains important safety information.

Before operating the unit, read this manual thoroughly and keep it
with the truck body at all times. See quick start guide first.

This page left intentionally blank

TABLE OF CONTENTS
I N T R O D U C T I O N ...........................................................................................................................2
Using Your Operators Manual....................................................................................................2

S Y S T E M S A F E T Y W A R N I N G S ...............................................................................................3
Safety Warnings and Precautions...............................................................................................3
Safety Labels and Locations.......................................................................................................5

Q U I C K S T A R T G U I D E ................................................................................................................7
Refrigeration System Diagram....................................................................................................8
Daily Operating Instructions........................................................................................................9

S Y S T E M S P E C I F I C A T I O N S A N D T E C H N I C A L D A T A .................................................10
R E F R I G E R A T I O N .........................................................................................................................12
All-Electric Cold Plate System....................................................................................................12
Defrost and Cooling Cycle..........................................................................................................15
Preventative Maintenance Checklist..........................................................................................17

O P E R A T O R T R O U B L E S H O O T I N G .........................................................................................20
Troubleshooting Chart................................................................................................................20

B O D Y C A R E A N D M A I N T E N A N C E .......................................................................................22
Fiberglass Maintenance and Repair...........................................................................................22
Other Body Care and Maintenance............................................................................................24

C O L D C H A I N B E S T P R A C T I C E S ...........................................................................................25
G L O S S A R Y .....................................................................................................................................27
W A R R A N T Y ....................................................................................................................................29
S E R V I C E A N D S U P P O R T ..........................................................................................................30
Service Contacts.........................................................................................................................30
Service Record Log.....................................................................................................................31

-1-

This page left intentionally blank

INTRODUCTION
USING YOUR OPERATORS MANUAL
This operators manual contains important information about your Johnson Refrigeration System 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 and refrigeration system receive periodic inspections, maintenance, and service parts
replacement.
This manual includes safety checks that the operator must perform periodically. Reading your operators
manual will help you and others avoid personal injury or damage to the system. The information in this manual
will provide the operator with the safest and most effective use of the refrigeration system. Knowing how to
operate your refrigeration system safely and correctly will allow you to train others on the proper operation of
this piece of equipment.
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. It is
recommended that you use similar preventative maintenance practices with regard to this refrigeration system.

ATTENTION
Read this manual carefully and become familiar with your Johnson Refrigeration System. Know its
applications, its limitations and any hazards involved. Should you have any further questions, contact
Johnson Refrigerated Truck Bodies at (800)922-8360 and ask for the Customer Service Department. This
manual should be kept with the body at all times and should remain with the body when it is sold.

-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 which, if not avoided, will result in death
or serious injury. WARNING indicates a hazard which, if not avoided, could result in death or serious injury.
CAUTION indicates a hazard which, 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 all services be performed by a qualified service
technician. However, there are several general safety practices which you should be aware of.
WARNING: Always wear safety glasses or goggles when working with or around the refrigeration system
or battery. Refrigerant or battery acid 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 the unit is connected to shore power and the compressor on/off
switch is turned ON.
WARNING: Be sure to disconnect power supply when inspecting any part of the unit.

Electrical hazard
WARNING: Be sure to disconnect unit from shore power before working on the unit. This is an allelectric unit and could present a potential electrical hazard.

-3-

Lift gate
For body applications where there is a side or rear mounted lift gate, please see the manufacturers owners
manual for safety and operational instructions.

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.
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.
-4-

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.

CAUTION connecting/disconnecting to shore power

Applied to all electrical system outlets. Depending on which
type, also includes voltage and phase.

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.

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.

DANGER high voltage

Located on the top of the power inverter.

DANGER
HIGH VOLTAGE
DISCONNECT SHORE POWER
AND TURN OFF CIRCUIT BREAKER
ON THIS UNIT BEFORE SERVICING

ATTENTION connecting/disconnecting to shore power

Located near shore power outlet on the driver side front
cornershell of the body.

ATTENTION!
Turn Electric On/Off to OFF BEFORE connecting or
disconnecting to shore power.
Not following this procedure can cause damage to the electrical system

-5-

Truck body safety labels

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.

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

OVER ALL
HEIGHT
12 6

Over-all height notice

Located on the driver-side front cornershell above the
thermometer housing on all trucks reaching 12 6 in height.

Emergency release notice

Only found on models with a push bar feature on the body
door(s). Decal located inside the door pan along side
push bar.

PUSH
EMERGENCY RELEASE
CHECK OPERATION
FREQUENTLY

ATTENTION vacuum relief port

Located inside body on the front curbside cornershell wall
next to vacuum relief port. Keep port free from
obstruction to prevent blockage. (Low temperature only)

ATTENTION:
VACUUM RELIEF PORT
Keep Free From Obstruction

N O T I C E

NOTICE safety release

Located inside every door of body above the release
handle. All doors are equipped with an inside safety
release feature, so a person can never be locked inside
the body.

THIS DOOR IS EQUIPPED WITH

AN INSIDE SAFETY RELEASE.

YOU CANNOT BE LOCKED INSIDE.

FOR EMERGENCY EXIT, UNSCREW
T HANDLE COUNTERCLOCKWISE
AND PUSH DOOR OPEN.

CAUTION required maintenance

Located inside every door of body above the release
handle.

CAUTION
REQUIRED MAINTENANCE
DISASSEMBLE INTERNAL DOOR
RELEASE HANDLE AND LUBRICATE
THREADS ANNUALLY

OPEN
Located inside every door of body below the T release
handle. All doors are equipped with an inside safety
release feature, so a person can never be locked inside
the body.
-6-

This page left intentionally blank

-6-

Read This First

Quick Start Guide

TO YOUR JOHNSON REFRIGERATION SYSTEM
Set-up and Daily Operation

All-Electric Cold Plate System

LOW TEMPERATURE

QUICK START CONTENTS

Refrigeration System Diagram
Daily Operating Instructions
PRE-COOLING INSTRUCTIONS
PROPER LOADING INSTRUCTIONS
ROUTE OPERATION
RETURNING FROM ROUTE

Set-up and Daily Operation Instructions

Before operating the system, please read this Quick Start Guide and the Operators Manual
completely, and retain them for future reference. Carefully observe all warnings, precautions,
and instructions on the refrigeration system and adhere to them.

-7-

REFRIGERATION SYSTEM DIAGRAM

Read this Operators Manual and safety rules before operating your Johnson Refrigeration System.
Compare the illustration with your refrigeration system to familiarize yourself with the locations of this systems main components and airflow.
Save this manual for future reference.

All-Electric Cold Plate System:

Low temperature

Airflow
Cold air

Compressor/condenser
nose mount

Warm air
Eutectic cold plates

Compressor
on/off switch

Cornershell
thermometer

Compressor/condenser
skirt mount

Shore power
outlet

Cord box

a. Compressor on/off switch located on the driver side front cornershell of the body. Switch must be turned
OFF when connecting or disconnecting unit from shore power.
b. Compressor/condenser (nose and skirt mount) unit works as both a motor and a pump that moves
refrigerant through the system.
c. Eutectic cold plates when system is plugged into shore power, refrigerant passes through cold plates
recharging the salt brine/eutectic solution within approximately eight hours.
d. Cornershell thermometer digital thermometer which allows operator to monitor bodys interior air
temperature; located on driver side front cornershell of the body.
e. Shore power outlet 3-Phase/1-Phase outlet used to plug refrigeration system into shore power to be
recharged; located on the driver side front cornershell.
f. Cord box if truck comes with a cord box feature, the line cord is located in the white box on the driver side
of the truck. Cord box cover must be closed and latched in order to activate the ignition cut-out switch,
allowing the truck to be started.

-8-

DAILY OPERATING INSTRUCTIONS

PRE-COOLING INSTRUCTIONS
Pre-cool the truck before loading product
1. Turn compressor on/off switch to OFF. It is located on the driver side front
cornershell.

Compressor on/off switch

2. Retrieve the electrical line cord provided inside the chassis cab. If truck
has a cord box feature, line cord can be found on the driver side mounted
to the body sub-floor.
Cord box

In-cab line cord

3. Plug the unit into shore power (see glossary).

Shore power plug-In

4. Turn the compressor on/off switch to ON.

On/off switch

5. Let the compressor run for a minimum of eight uninterrupted hours until the
refrigeration plates are recharged. It will then shut off by a pressure switch.
6. Refer to cornershell thermometer to verify the unit has reached the appropriate
temperature before loading your product.
NOTE: The bodys interior air temperature will be higher after loading product.
Cornershell thermometer

7. Before going en route, turn compressor switch to OFF. Unplug and stow power cord.
If truck has a cord box, cover must be fully closed and latched to activate the ignition
cut-out switch, allowing the truck to be started.

PROPER LOADING INSTRUCTIONS

Loading the product into the truck
Proper loading practices will help insure the appropriate environment for temperature-controlled product, and
will optimize the refrigeration performance to insure delivery of the highest quality products. All products must
be loaded in a manner that allows for an envelope of air to circulate around the sides, top, front, back and
underside of the product. Proper air circulation is critical to maintaining the desired product temperature.
NOTE: Product must be pre-cooled to the proper temperature before loading. The unit is designed to maintain
product temperature, not to pull down product temperature.

RETURNING FROM ROUTE

Complete the following steps to recharge capacity of the cold plates for next route cycle
1. Park truck at a location where it can be plugged into shore power.
2. Retrieve the electrical line cord.
3. Make sure the compressor on/off switch is turned to OFF.
4. Plug the unit into shore power to energize the system.
5. Turn the compressor on/off switch to ON.
6. The compressor must run for approximately eight uninterrupted hours until the
refrigeration plates are recharged. It will then shut off by a pressure switch.
Your truck is now ready for your next route cycle.
-9-

SYSTEM SPECIFICATIONS AND TECHNICAL DATA

All-Electric Low Temperature Cold Plate Refrigeration System, for 0 Operation (up to 96 inch wide bodies)
BODY LENGTH:
TOTAL BTU/HR HEAT
LOAD REQUIREMENT

12 Ft Body

14 Ft Body

7062

7937

NOTE: THE BTU PER HOUR LOAD CALCULATION ABOVE IS BASED ON AN AMBIENT OF

MODEL ID#:

16 Ft Body

18 Ft Body

20 Ft Body

22 Ft Body

24 Ft Body

26 Ft Body

8811

9686

10560

11435

12309

13184

110

DEGREES, FOLLOWING STANDARD INDUSTRY COLD CHAIN MANAGEMENT PRACTICES.

L100PV1 -V3 - 12

L100PV1 -V3 - 14

L100PV1 -V3 - 16

L100PV1 -V3 - 18

L100PV1 -V3 - 20

L100PV1 -V3 - 22

L100PV1 -V3 - 24

L100PV1 -V3 - 26

12 Ft Body

14 Ft Body

16 Ft Body

18 Ft Body

20 Ft Body

22 Ft Body

24 Ft Body

26 Ft Body

CONDENSING UNIT:
Single Phase
Compressor
Temperature Application
Condensing Unit Model #
Compressor Model #
Minimum Circuit Ampacity
Compressor RLA
Compressor BTU/HR
Capacity @ Ambient
Voltage Rating:
Line Voltage Minimum
Line Voltage Maximum
Oil Type
Oil Quantity
Refrigerant - R404A
Pressure Settings:
Cut IN
Cut Out
Total System Weight

Ambient Operating
Temperature (F)
Plate Specification:
Plate Blower Cabinet Size
Ceiling Plate Size:
Ceiling Plate Size:
Front Wall Plate Size:
Front Wall Plate Size:
Solution Temperature (F)

Three Phase
Compressor

Single Phase
Compressor

Three Phase
Compressor

Single Phase
Compressor

Three Phase
Compressor

Single Phase
Compressor

Three Phase
Compressor

Single Phase
Compressor

Three Phase
Compressor

Single Phase
Compressor

Three Phase
Compressor

Three Phase
Compressor

Single Phase
Compressor

Single Phase
Compressor

Three Phase
Compressor

Low Temperature ( 0 Deg)

TJAL-030Z
ZF13K4E-PFV
ZF13K4E-TF5
36.0
21.3
26.8
15.0

Low Temperature ( 0 Deg)

TJAL-030Z
ZF13K4E-PFV
ZF13K4E-TF5
36.0
21.3
26.8
15.0

Low Temperature ( 0 Deg)

TJAL-040Z
ZF15K4E-TF5
ZF15K4E-PFV
42.3
29.3
31.8
21.4

Low Temperature ( 0 Deg)

TJAL-040Z
ZF15K4E-TF5
ZF15K4E-PFV
42.3
29.3
31.8
21.4

Low Temperature ( 0 Deg)

TJAL-022Z (2)
ZF09K4E-PFV
ZF09K4E-TF5
46.0
32.8
32.8
22.2

Low Temperature ( 0 Deg)

TJAL-030Z (2)
ZF13K4E-PFV
ZF13K4E-TF5
72.0
42.6
53.6
30.0

Low Temperature ( 0 Deg)

TJAL-030Z (2)
ZF13K4E-PFV
ZF13K4E-TF5
72.0
42.6
53.6
30.0

Low Temperature ( 0 Deg)

TJAL-030Z (2)
ZF13K4E-PFV
ZF13K4E-TF5
72.0
42.6
53.6
30.0

12090

12090

14770

14770

17800

24180

24180

24180

197
253
Ultra 32-3 MAF Polyol Ester
64 OZ
21 lbs
`
14#
4#
1921

197
253
Ultra 32-3 MAF Polyol Ester
64 OZ
21 lbs
`
14#
4#
2070

197
253
Ultra 32-3 MAF Polyol Ester
64 OZ
21 lbs

197
253
Ultra 32-3 MAF Polyol Ester
64 OZ
21 lbs

197
253
Ultra 32-3 MAF Polyol Ester
50 OZ
21 lbs

197
253
Ultra 32-3 MAF Polyol Ester
64 OZ
21 lbs

197
253
Ultra 32-3 MAF Polyol Ester
64 OZ
21 lbs

197
253
Ultra 32-3 MAF Polyol Ester
64 OZ
21 lbs

14#
4#
2250

14#
4#
2416

14#
4#
2989

14#
4#
3255

14#
4#
3433

14#
4#
3613

110

110
Quantity

Thickness
2-1/8"

Thickness
2-1/8"

NA
30" X 120"
NA
30" X 74"
NA

110
Quantity

Thickness
2-1/8"

NA
2
2

30"
30"
30"
36"

X 74"
X 60"
X 74"
X 74"

110
Quantity

Thickness
2-1/8"

NA
2
2
1
1

30"
30"
30"
36"

X 84"
X 74"
X 74"
X 74"

110
Quantity

Thickness
2-1/8"

NA
2
2
1
1

30"
30"
30"
36"

X 96"
X 84"
X 74"
X 74"

110
Quantity

Thickness
2-1/8"

30"
30"
30"
36"

2
4
1
1

X 74"
X 66"
X 74"
X 74"

Thickness
2-1/8"

NA

NA
2
2
1
1

110
Quantity

30"
30"
30"
36"

Thickness
2-1/8"

NA
2
4
1
1

X 96"
X 66"
X 74"
X 74"

110
Quantity

30" X 84"
NA
30" X 74"
36" X 74"

Quantity
NA

6
0
1
1

30"
30"
30"
36"

X 96"
X 84"
X 74"
X 74"

4
2
1
1

-14

-14

-14

-14

-14

-14

-14

-14

Cold Plate BTU/HR

Capacity (F)
Total Surface Area

7518
176.6

8323
197.1

9262
218.5

10125
238.1

10803
263.1

11666
282.7

12905
303.9

13846
325.5

Total BTU/Hr Required

Surface Area Required

7062
252.2

7937
283.4

8811
314.7

9686
345.9

10560
377.1

11435
408.4

12309
439.6

13184
470.8

7518

8323

9262

10125

10803

11666

12905

13846

Total System
BTU/HR Capacity (F)
Condensing Unit
Operating Time
Required
Holdover Available

7.76

8.86

7.86

7.86

7.86

7.86

7.86

7.86

10.65

10.49

10.51

10.45

10.23

10.20

10.48

10.50

- 10 -

All-Electric Low Temperature Cold Plate Refrigeration System, for -5 Operation (up to 96 inch wide bodies)
BODY LENGTH:
TOTAL BTU/HR HEAT
LOAD REQUIREMENT

12 Ft Body

14 Ft Body

16 Ft Body

18 Ft Body

20 Ft Body

22 Ft Body

24 Ft Body

26 Ft Body

6705

7535

8366

9197

10028

10859

11689

12520

NOTE: THE BTU PER HOUR LOAD CALCULATION ABOVE IS BASED ON AN AMBIENT OF

MODEL ID#:

110

DEGREES, FOLLOWING STANDARD INDUSTRY COLD CHAIN MANAGEMENT PRACTICES.

L100PV1 -V3 - 12

L100PV1 -V3 - 14

L100PV1 -V3 - 16

L100PV1 -V3 - 18

L100PV1 -V3 - 20

L100PV1 -V3 - 22

L100PV1 -V3 - 24

L100PV1 -V3 - 26

12 Ft Body

14 Ft Body

16 Ft Body

18 Ft Body

20 Ft Body

22 Ft Body

24 Ft Body

26 Ft Body

CONDENSING UNIT:
Single Phase
Compressor
Temperature Application
Condensing Unit Model #
Compressor Model #
Minimum Circuit Ampacity
Compressor RLA
Compressor BTU/HR
Capacity @ Ambient
Voltage Rating:
Line Voltage Minimum
Line Voltage Maximum
Oil Type
Oil Quantity
Refrigerant - R404A
Pressure Settings:
Cut IN
Cut Out
Total System Weight

Ambient Operating
Temperature (F)
Plate Specification:
Plate Blower Cabinet Size
Ceiling Plate Size:
Ceiling Plate Size:
Front Wall Plate Size:
Front Wall Plate Size:
Solution Temperature (F)

Three Phase
Compressor

Single Phase
Compressor

Three Phase
Compressor

Single Phase
Compressor

Three Phase
Compressor

Single Phase
Compressor

Three Phase
Compressor

Single Phase
Compressor

Three Phase
Compressor

Single Phase
Compressor

Three Phase
Compressor

Single Phase
Compressor

Three Phase
Compressor

Single Phase
Compressor

Three Phase
Compressor

Low Temperature ( 0 Deg)

TJAL-040Z
ZF15K4E-PFV
ZF15K4E-TF5
42.3
29.3
31.8
21.4

Low Temperature ( 0 Deg)

TJAL-040Z
ZF15K4E-PFV
ZF15K4E-TF5
42.3
29.3
31.8
21.4

Low Temperature ( 0 Deg)

TJAL-030Z (2)
ZF13K4E-TF5
ZF13K4E-PFV
72.0
42.6
53.6
30.0

Low Temperature ( 0 Deg)

TJAL-030Z (2)
ZF13K4E-PFV
ZF13K4E-TF5
72.0
42.6
53.6
30.0

Low Temperature ( 0 Deg)

TJAL-030Z (2)
ZF13K4E-PFV
ZF13K4E-TF5
72.0
42.6
53.6
30.0

Low Temperature ( 0 Deg)

TJAL-030Z (2)
ZF13K4E-PFV
ZF13K4E-TF5
72.0
42.6
53.6
30.0

Low Temperature ( 0 Deg)

TJAL-030Z (2)
ZF13K4E-PFV
ZF13K4E-TF5
72.0
42.6
30.0
53.6

Low Temperature ( 0 Deg)

TJAL-030Z (2)
ZF13K4E-PFV
ZF13K4E-TF5
42.6
72.0
53.6
30.0

13380

13380

21900

21900

21900

21900

21900

21900

197
253
Ultra 32-3 MAF Polyol Ester
64 OZ
21 lbs

197
253
Ultra 32-3 MAF Polyol Ester
64 OZ
21 lbs

197
253
Ultra 32-3 MAF Polyol Ester
50 OZ
21 lbs

197
253
Ultra 32-3 MAF Polyol Ester
50 OZ
21 lbs

197
253
Ultra 32-3 MAF Polyol Ester
64 OZ
21 lbs

197
253
Ultra 32-3 MAF Polyol Ester
64 OZ
21 lbs

197
253
Ultra 32-3 MAF Polyol Ester
64 OZ
21 lbs

197
253
Ultra 32-3 MAF Polyol Ester
64 OZ
21 lbs

14#
4#
2153

14#
4#
2330

14#
4#
3021

14#
4#
3195

14#
4#
3429

14#
4#
3603

14#
4#
3807

14#
4#
4356

110
Thickness
2-5/8"

110
Quantity

Thickness
2-5/8"

30" X 74"
30" X 60"
30" X 74"
36" X 74"

NA
30" X 120"
NA
30" X 74"
NA

110
Quantity

Thickness
2-5/8"

2
2
1
1

30" X 84"
30" X 74"
30" X 74"
36" X 74"

NA

110
Quantity

Thickness
2-5/8"

Thickness
2-5/8"

2
2
1
1

30" X 74"
30" X 66"
30" X 74"
36" X 74"

NA

NA
2
2
1
1

30"
30"
30"
36"

110

110
Quantity

X 96"
X 84"
X 74"
X 74"

Quantity

Thickness
2-5/8"

2
4
1
1

30" X 96"
30" X 66"
30" X 74"
36" X 74"

NA

110
Quantity

Thickness
2-5/8"

2
4
1
1

30" X 84"
NA
30" X 74"
36" X 74"

110
Quantity

Thickness
2-5/8"

NA

NA

Quantity
NA

6
1
1

30"
36"
30"
36"

X 96"
X 84"
X 74"
X 74"

4
2
2
1

-21

-21

-21

-21

-21

-21

-21

-21

Cold Plate BTU/HR

Capacity (F)
Total Surface Area

8339
180

9167
201.1

10218
223.1

11336
243.1

12311
268.3

13429
288.3

14476
310.7

17310
379.54

Total BTU/Hr Required

Surface Area Required

6705
209.5

7535
235.5

8366
261.4

9197
287.4

10028
313.4

10859
339.3

11689
365.3

12520
391.3

8339

9167

10218

11336

12311

13429

14476

17310

7.35

8.26

5.28

5.28

5.28

5.28

5.28

5.28

12.44

12.17

12.21

12.33

12.28

12.37

12.38

13.83

Total System
BTU/HR Capacity (F)
Condensing Unit
Operating Time
Required
Holdover Available

- 11 -

REFRIGERATION
Read this Operators Manual and safety rules before operating your Johnson Refrigeration System.
Compare these images with your refrigeration system to familiarize yourself with the locations of this systems main components.
Save this manual for future reference.

ALL-ELECTRIC COLD PLATE SYSTEM:

Low temperature

- 12 -

ELECTRICAL SYSTEM COMPONENTS

1-Phase plug-in: Female receptacle
(left) male plug (right). 30-amp, 250-volt
AC power. Three prong, twist-lock
connector, located on line cord end.
NEMA #L6-30 plug and receptacle.

3-Phase plug-in: Female receptacle

(left) male plug (right). 30-amp, 250-volt
AC power. Four prong, twist lock
connector, located on line cord end.
NEMA #L15-30 plug and receptacle.

Depot shore power: Electrical

power source where a truck can be
parked and plugged-in to recharge
refrigeration system overnight.

Shore power outlet:

1-Phase or 3-Phase outlet used to
plug refrigeration system into shore
power to be recharged. Located on
the driver side front cornershell of the
body.

- 13 -

GROTE LIGHT SWITCH OPERATION AND PROGRAMMING

(Feature optional)

OPERATING INSTRUCTIONS
Turn on:
Press and release the pushbutton located on the driver side cornershell. The gold LED indicator above
pushbutton will turn on to indicate the body interior lights are active. This automatically begins the delay
time duration (40-minute default setting).
NOTE: If the LED indicator flashes at a high rate, the body interior lights will not turn on because the
brake input is active.
Turn off:
To manually turn OFF the body interior lights, press and release the pushbutton. The LED indicator
above pushbutton will also turn off to indicate the body interior lights have been turned off.
The body interior lights and LED indicator will both turn off once the delay time expires.
The body interior lights and LED indicator will both turn off when the brake pedal has been pressed for a
minimum of one second. The LED indicator will then flash 10 times at a high rate to signify that the
brakes have shut down the body interior lights.

PROGRAMMING DELAY TIME

The body interior lights must be turned off before entering program mode.
1. Press and hold the pushbutton for 10 seconds until the LED indicator turns off, then release the
pushbutton.
2. Press and release the pushbutton the number of times required to set the MODE, to achieve the
desired delay time. (Refer to chart below)
MODE
1
2
3
4

Delay time (minutes)

20
40 (default setting)
60
90

3. Wait five seconds to allow the timer to exit programming mode. When the timer has been successfully
programmed, it will flash the LED indicator a number of times to indicate the new MODE setting.
NOTE: If the five seconds expire before entering a new MODE setting, the timer will respond by simply
flashing the current MODE. This feature can be used to verify the current setting.

- 14 -

DEFROST AND COOLING CYCLE

COLD PLATE DEFROST
To prevent frost build-up on the surface of the plates, run cold plate defrost brush mounted above curbside door
on body interior (feature optional) across plates surface daily. Avoid contact with refrigeration piping and
valves. It is not recommended to use scrapers on plates. Expansion valves could be jarred in the process,
resulting in a refrigerant leak. It could also result in scraping the surface or puncturing the plates.
A cold plate manual defrost is recommended to be performed once a week, and is required when frost
accumulation exceeds build-up on plate surface.
To conduct a manual defrost, complete the following
1. Compressor on/off switch should be OFF.
2. Unplug power supply.
3. Unload product, and open all body doors. (NOTE: Ambient air temperature must be above freezing.)
4. Place a fan in rear door opening directing warm airflow onto plates or use water hose with a sprayer
using warm water directed onto plates. (IMPORTANCE NOTICE: Water temperature should not
exceed 110F as excessive heat build-up in the plates can create expansion beyond what the plates
are designed. Do not use a high pressure wash system. Doing so could damage plate surface, piping
or valves. Use only standard household water pressure. Do not direct water flow at evaporator unit,
electrical enclosures, or light fixtures.)
5. When plates are defrosted, flush out floor and shelving, sanitizing as required.
6. Dry interior of body and plates with a fan.
After Defrost
1. Compressor on/off switch should be OFF.
2. Plug in power cord.
3. Turn compressor on/off switch to ON. When unit starts observe for one to two minutes before leaving.

- 15 -

COOLING CYCLE
The cooling system operates from shore power connection. While this system is activated, the unit must remain
plugged into shore power and uninterrupted throughout the entire duration of the cooling cycle. A minimum of
eight hours continuous compressor run is recommended.
The system consists of one condensing unit with one condenser, either sub floor (a) or nose mount (b), and
eutectic cold plates (c). The condensing unit is controlled by a low pressure cut-out switch, and will run until the
eutectic plates are frozen and the setpoint temperature inside the body is reached. When the cold plates are
fully charged, the compressors will cycle off on the pressure control.
IMPORTANT NOTICE: ONCE COMPRESSOR ON/OFF SWITCH IS TURNED ON, COMPRESSOR MAY
START AT ANY TIME, WHETHER OR NOT TRUCK ENGINE IS RUNNING.

a.)

b.)

c.)

- 16 -

PREVENTATIVE MAINTENANCE
It is important that every refrigerated truck body owner and/or operator have an organized preventative
maintenance program. A closely followed preventative maintenance program will help to keep your
Johnson Refrigeration System in top operating condition. The following general schedule is provided
to assist in monitoring that maintenance.

EN ROUTE OBSERVATIONS
En route inspections are recommended every four hours for the prevention of damage to the cargo.
9 Body temperature reading should be within 5 to 8F of the thermostat setting. If the body temperature is
not within 5 to 8F, it indicates one of the following:
a) The unit has not had sufficient time to pull down to setpoint temperature (i.e. warm load,
improperly pre-cooled body, length of time on route, frequency of door openings, etc.)
b) Frost or ice accumulation on cold plates exceeds build-up on plate surface. Manual cold
plate defrost is required.
c) Unit may be low on refrigerant charge. If bubbles appear in the liquid line sight glass,
refrigerant may be low. Maintenance check of system charge required.
(Also refer to Operator Troubleshooting section of this manual)
Cargo area inspection
Johnson Refrigeration Systems are designed to maintain the required temperature for product being carried
during time of transit. To assist the unit in performing this function, operators should:
9 Inspect the body for proper insulation.
9 Inspect outside of body for loose or improperly sealed doors.
9 Inspect inside of body for damaged walls and clogged defrost drain tubes. Any damage to the wall or
insulation must be repaired (see Body Care and Maintenance section of this manual)
9 Be sure loads are at the proper carrying temperature when you pick them up.
9 Supervise loading to make sure there is sufficient air space around the load for proper air circulation.

DAILY OBSERVATIONS
Condenser surface
9 Remove any debris that may have lodged itself into the condenser fins while en route (i.e. leaves,
branches, wrappers, bags, etc.)
Line cord inspection
9 View line cord for any cuts, nicks, chafing or abrasions that may indicate damage to the line cord wires.
9 While condensing unit is operating, feel line cord ends. If cord ends are hot to the touch, disconnect
power supply and check the electrical connections of the line cord wires to the contact prongs.
9 View line cord ends and plug-ins (flanged inlet), and male plug prongs for any burnt spots on connector
contacts. Replace components with any damaged or burnt contacts before operating equipment.
Cold plate defrost
To prevent frost build-up on the surface of the plates, run cold plate defrost brush mounted above curbside door
on body interior (feature optional) across plates surface daily. Avoid contact with refrigeration piping and
valves. It is not recommended to use scrapers on plates. Expansion valves could be jarred in the process,
resulting in a refrigerant leak. It could also result in scraping the surface or puncturing the plates.
A cold plate manual defrost is recommended to be performed once a week, and is required when frost
accumulation exceeds build-up on plate surface.
9 To conduct a manual defrost, complete the following:
1. Compressor on/off switch should be OFF.
2. Unplug power supply.
3. Unload product and open all body doors. (NOTE: Ambient air temperature must be above
freezing.)
4. Place a fan in rear door opening directing warm airflow onto plates or use water hose with a
sprayer using warm water directed onto plates. (IMPORTANT NOTICE: Water temperature
should not exceed 110F as excessive heat build-up in the plates can create expansion beyond
what the plates are designed. Do not use a high pressure wash system. Doing so could
- 17 -

damage plate surface, piping or valves. Use only standard household water pressure. Do not
direct water flow at evaporator unit, electrical enclosures, or light fixtures.)
5. When plates are defrosted, flush out floor and shelving, sanitizing as required.
6. Dry interior of body and plates with a fan.
9 After defrost, complete the following:
1. Compressor on/off switch should be OFF.
2. Plug in power cord.
3. Turn compressor on/off switch to ON. When unit starts, observe for 1-2 minutes before leaving.

MONTHLY OBSERVATIONS
Exterior condenser fins
9 Check for exterior condenser fins that may be bent. Fins that are bent need to be combed out or
straightened to allow airflow through condenser.
9 Remove any accumulated dirt and/or debris by running water across the surface of the fins.
NOTE: Do not use a high pressure wash system to clean condensing unit. Doing so will damage
condenser fins. Use only standard household water pressure.
Compartment
9 Open compressor compartment door or roof top service cover and check for any oil stains or signs of oil
leaks. If stains are present contact Johnson Refrigerated Truck Bodies or a qualified service technician
for further steps.
Holdover plate system
9 Check for frost or ice build-up on holdover plates. If build-up exceeds on the plate surface, the
system needs to be defrosted.
9 Upon system defrost, inspect condition of holdover plates for any external leaks.
9 Check all plate fittings and piping.
9 Check all holdover plate mounting brackets and support channels inspecting for loose fasteners or
clamping fixture failures.

QUARTERLY OBSERVATIONS
Refrigeration system
9 On the condensing unit, clean the condenser coil with a garden hose sprayer. Take care not to
damage the aluminum fins. Clean condenser coils will prolong the life of your compressors, and allow
your system to operate more efficiently.
9 While the compressors are operating, check oil sight glass. The oil level should be to full.
9 While the compressors are operating, check the liquid line sight glass. The fluid should be clear and the
moisture indicator should be green.
9 Check all wiring and capillary tubes of the controls. Be sure they are not chafing or rubbing against
anything.
9 Check the system for any oil spots. This would indicate the possible start of a small leak.

SIX-MONTH OBSERVATIONS
With condensing unit unplugged:
9 Remove roof top condensing unit service cover.
9 Remove any foreign debris (i.e. leaves, branches, dirt, ice, snow, etc.) from inside of condensing unit
compartment.
9 Look for signs of oil stains/leaks on compressor frame, hoses or floor of condensing unit compartment.
9 Check condenser fan motor and blade for cracks, nicks or contact points to condenser fan shroud.
9 Inspect copper tubing and/or hoses for chafing, rubbing, loose clamps, etc.
9 Check to see that discharge line thermostat is secured to the high side copper pipe on the compressor.
9 Inspect condenser frame for excessive corrosion, rust, cracks, loose or missing bolts/fasteners.
WARNING: To reduce the risk of serious physical injury, never reach into the
condensing unit compartment or condensing unit while the system is plugged into shore
power. Always disconnect power supply when servicing condensing unit. Servicing of
the condensing unit is only to be conducted by a certified refrigeration technician.
- 18 -

While compressor is operating:

9 View compressor sight glass for proper oil levels (levels should be within to full).
9 View liquid line sight glass for bubbles (may be an indicator of low refrigerant charge).

ADJUSTMENTS NEVER TO BE PERFORMED

The following tasks should never be conducted unless directed to do so by Johnson Refrigerated Truck Bodies.
Failure to obtain authorization and direction for refrigeration adjustments could result in warranty revocation,
refrigeration system failure, and possible serious physical injury to the operator.
Never try to adjust or reset interior holdover plate expansion valves. Valves are preset by the
manufacturer and do not need to be adjusted.
Never adjust the condensing unit dual pressure control. The high and low pressure cut in/outs are preset
by the manufacturer and do not need to be adjusted.
Never adjust the condensing unit fan control. Controls are preset by the manufacturer and do not need to
be adjusted.
Never adjust the defrost heater thermostat control. Thermostat is preset by the manufacturer and does
not need to be adjusted.
Never remove the condensing unit electrical control box cover unless directed to do so by a Johnson
Refrigerated Truck Body engineer.
WARNING: Removal and replacement of electrical components within the electrical control box could
cause major failure to the condensing unit as well as electrical hazards.

- 19 -

OPERATOR TROUBLESHOOTING
USING TROUBLESHOOTING CHART
If you are experiencing a problem that is not listed in this chart, contact JRTB Customer Service to speak with
an engineer. When you have checked all the possible causes and you are still experiencing the problem, see a
qualified service technician.
IMPORTANT NOTICE: Before performing any repair service or procedure, please refer to the Johnson
Refrigerated Truck Bodies Service Manual.

Troubleshooting Chart

Compressor will
not start or run
on shore power.

Body not holding

temperature.

1. No AC power to body.
2. Compressor on/off switch is in OFF
position.
3. System is off on pressure it is satisfied to
setpoint.
4. Loss of Freon.
5. Pump down switch in pump down position.

1. Check circuit breaker.

2. Make sure compressor on/off switch is
turned ON.
3. The plates are fully recharged.

1. Number/duration of door openings.

2. Number/duration of stops.

1. Limit number of door openings.

2. Does this exceed design criteria of
application?
3. Maintenance check to verify application.

3. Travel time between stops, and full duration

of route.
4. Temperature of product when loaded into
the truck.
5. Door strip curtains damaged or missing.

4. Install a manifold set and check for pressure.

5. Move switch to start till compressor starts
then put in run position.

6. Body insulation or door seals flattened,

damaged or cracked.

4. Be sure cargo is at the proper carrying

temperature when loaded.
5. Replace or repair damaged curtains. See
Body Care and Maintenance.
6. Replace or repair damaged insulation or door
seals. See Body Care and Maintenance.

1. Frost or ice accumulation on plates exceeds

build-up on plate surface. (shown below)

1. Cold plate manual defrost is required. See

Defrost and Cooling Cycle.

2. Expansion valves, piping or plate surface

may have been damaged, resulting in a
refrigerant leak.

2. Upon system defrost, inspect condition of

holdover plates, plate fittings and piping for
any external leaks.

1. Unit may have not had sufficient time to pull

down to desired temperature due to one of
the following:
a) Warm load
b) Improperly pre-cooled body.
c) Thermometer out of calibration.
2. Improper loading procedure.

1. a) Be sure product is at the proper carrying

temperature when loaded.
b) Review proper Pre-Cooling Instructions in
the Quick Start Guide
c) Use a secondary thermometer to verify
thermometer is not out of calibration.
2. Supervise loading to make sure there is
sufficient air space around the load for
proper air circulation.
3. Maintenance check of system charge if
required.

Eutectic cold
plates not
operating
properly.

Body temperature
does not read
within 5-8 of
desired
temperature.

3. Unit may be low on refrigerant charge. If

bubbles appear in the liquid line sight glass,
refrigerant may be low.

- 20 -

1. Arcing caused by routinely plugging

and unplugging unit from shore power
while the compressor on/off switch is
left ON. (shown below)

Line cord ends are

hot to the touch
when condensing
unit is running.

NOTE: Always turn compressor on/off switch OFF

when plugging or unplugging unit from
shore power.
2. Line cord wires may be worn or
damaged.
3. High Amp draw.
1. Low Freon.

Condensing unit
starts, but does
not continue to
run.
For 3-Phase
compressors that
have power, but
will not start.

1. Disconnect power supply and check the

electrical connections of the line cord wires to the
contract prongs. Look for burnt spots on
connector contacts. Replace components with
any damaged or burnt contacts before operating
equipment.

2. View line cord for any cuts, nicks, chafing or

abrasions. Replace components with damaged
or burnt contacts before operating equipment.
3. Adjust CRO to low pressure setting

3. Cutting out on high head pressure.

1. Check level in site glass on condensing unit.

Site glass should be clear with no bubbles.
2. Check pressure settings on dual pressure
control.
3. Make sure the condenser fan motor is working.

1. Check for proper voltage to the phase

correction module.

1. Disconnect power and change two legs of inlet

voltage on body plug in.

2. Compressor is short cycling.

NOTE: This should be done by a qualified service

technician.

- 21 -

BODY CARE AND MAINTENANCE

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.

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
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

- 22 -

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 customers specifications (i.e. gel coat with Cooks
Armorcoat Gel Coats or paint with DuPonts Imron or PPGs 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
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 area with resin (mixed according to manufacturers 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
- 23 -

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 manufacturers 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

OTHER BODY CARE AND MAINTENANCE

Cleaning body interior
Clean and sanitize body interior after cold plate defrost.
9 After defrosting unit, spray down walls using an all-purpose cleaner.
9 Rinse down walls using a water hose or pressure washer (2,600 lbs or less).
9 Wipe down or let air dry.
Interior drain holes
9 After defrost, make sure drains are clear of debris and check for proper drainage.
9 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.
9 Wipe away any build-up and make sure surfaces are kept clean.
9 Check for any visible tears.
9 Check that adhesive is holding. If coming loose, use 3M 4799 rubber cement glue to re-attach.
9 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.
9 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.
9 Shake can before using.
9 Hold can 6-8 inches from work surface. Do not spray with can in inverted position.
9
9
9
9

Grease square-butt hinges.

Check that set-screws on handles are tight.
Check and tighten body tie-down bolts.
Disassemble internal door release handle and lubricate threads annually to assure proper door handle
release function.

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.
- 24 -

COLD CHAIN BEST PRACTICES GUIDE

Cold chain is an uninterrupted supply system that manages a constant cold temperature, helping ensure product
safety and stability. The following practices are recommended for product protection during the loading,
transport and delivery process. Proper practices help ensure the appropriate environment for your temperaturecontrolled product, and will optimize refrigeration system performance.

LOADING, TRANSPORT AND DELIVERY

Product MUST be stored and loaded the required temperature for the product
Pre-cool, store, and verify product is at the proper temperature before loading. Refrigeration units are designed to maintain
product temperature, not to pull down product temperature.
Use dependable packaging
Materials must be durable, crush-resistant.
Vented containers for
fresh products

Non-vented containers for

low temperature or deep
frozen products

Block pallets for sufficient

air circulation

Verify set-point temperature

Confirm set-point temperature via the in-cab control feature (factory set) or
thermostat located inside the body.

Pre-cool truck body by activating refrigeration

Pre-cool body to set-point temperature. Refer to cornershell thermometer to verify unit has reached
the appropriate temperature before loading product. While en route, refer to in-cab control screen
thermometer (if applicable).
Loading product
Load quickly to minimize inside and outside air exchange. Allow for an envelope of air to circulate around the sides, top,
front, back and underside of the product when loading. Proper airflow is critical to maintaining required product
temperature. Load cargo securely to prevent the risk of shifting and damage to product during handling and transit.
NOTE: The bodys interior air temperature will be higher after loading product.
Minimize door openings
Limit the number and duration of door openings to minimize inside and outside air exchange.

Always use door strip curtains

Install and/or maintain door strip curtains properly to help reduce internal and external air exchange
while loading product.
Allow for body temperature recovery
Body temperature recovery time will increase with the entry of ambient air. Allow time for refrigeration system to recover
from door openings. The greater the temperature gap between the set-point temperature and actual body temperature, the
more time it will take to recover to set-point.
Loading/delivering product at docking station
Position body tightly against and maintain an effective seal between body and dock. Move product quickly to limit
exposure to non-refrigerated areas.
Defrost system regularly
Monitor system automatic defrost cycle, or initiate a system defrost when frost/ice accumulates on
evaporator coil or eutectic cold plates to ensure optimal refrigeration performance.
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PROPER AIRFLOW
Proper airflow is critical to maintaining required product temperature. Even with optimal system performance,
obstructions create poor air circulation and uneven temperature distribution, risking damage to your product.
Truck body interior must be kept clean to prevent contamination and obstruction of airflow. Clear body floor of all debris to
prevent circulation blockage, and check evaporator unit regularly to make sure it is free of debris.
Keep floor beneath product open so warm air can return back through cooling system. Block pallets help provide an airflow
channel by forming additional space between body floor and cargo.
Johnsons inverted tread airflow flooring option is designed to ensure sufficient airflow on the
underside of the product. The inverted channels provide a means for air to pass beneath the
product, while the foam insulation below the floor acts as a barrier to keep body floor cool.
Secure pallet loads with plastic netting instead of stretch film, which severely restricts proper
ventilation. Avoid using slip sheets or hand stacking as these are not favorable methods for adequate airflow.
Load product evenly to provide passable airways between top of the cargo and body ceiling when loading. Do not block
system warm air intake/cold air discharge, or load product tightly against walls or doors. This restricts airflow and will
negatively affect system cooling efficiency.

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GLOSSARY
This glossary is published for informational purposes only, and the information being furnished herein should
not be considered as all-inclusive or meant to cover all contingencies.
NOTE: Additional terms not found in the glossary may be located in the Index section of this manual.
1-Phase plug 30-amp, 250-volt AC power. Three prong, twist-lock connector, located on line cord end.
NEMA #L6-30 plug and receptacle. 1-Phase systems are offered as a special option.
3-Phase plug 30-amp, 250-volt AC power. Four prong, twist lock connector, located on line cord end. NEMA
#L15-30 plug and receptacle. 3-Phase systems are offered as the standard option.
Air temperature vs. product temperature The United States Food and Drug Administration requires that
frozen products be kept at a temperature in which they remain a frozen solid. This concept is often confused
with the air temperature, which is defined as a measure of the heat content in the air. The air temperature may
fluctuate due to door openings and/or other factors, but the product temperature must remain freezing.
Ambient air temperature is the temperature of the outdoor air surrounding the body.
Amp is the abbreviation for ampere, and the basic measuring unit of electrical current.
Arcing is caused by routinely plugging and unplugging unit from shore power while the compressor on/off
switch is left ON, and can have detrimental effects on your electronic equipment. Arcing damage on the
electrical components of this system can be indicated by burnt spots on electrical connections of the line cord
wires, connector contacts and prongs. (See the Operator Troubleshooting section of this manual.)
Body interior light switches can be used to control the bodys interior lights. The ON/OFF switch is located to
the right of the curbside door on body interior. The Grote switch is mounted on the driver side front cornershell;
gold LED light above pushbutton indicates the body interior lights are turned ON. The bodys interior lights turn
off automatically after delay time has expired (40-minute default setting) or when the brake pedal is depressed.
BTU (British thermal unit) is a common unit of measure for heat, and is equivalent to the amount of heat
energy required to heat one pound of water one degree Fahrenheit. For example, raising the temperature of
one pound of water from 40 degrees to 41 degrees would take one BTU. This form of measure is referred in
the capacity of this refrigeration system.
BTU capacity of this refrigeration system is based on the application criteria used to calculate the heat load that
the system is required to absorb and expel. BTU capacity of the system is referred to as the number of BTUs
per hour of heat that can be removed from the cargo area.
Coil is a cooling or heating element made of pipe or tube, formed into a helical or serpentine shape that may be
equipped with thin metal fins to aid heat transfer.
Cold plate defrost Prevent frost build-up on the surface of the plates by running cold plate defrost brush
mounted above curbside door on body interior (feature optional) across plates surface daily. A cold plate
manual defrost is recommended to be performed once a week, and is required when frost accumulation
exceeds build-up on plate surface.
Compressor/condensing unit is both a motor and a pump that moves refrigerant through the system. A vapor
compression pump uses a scroll method to compress refrigerant gas and send it to the condenser. The
condenser is a heat exchanger which removes heat from the hot compressed gas and allows it to condense into
a liquid. As a whole, this unit acts like the heart of the cooling system. It is controlled by a low pressure cut-out
switch, and will run until the eutectic plates are frozen and the setpoint temperature inside the body is reached.

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Compressor on/off switch is located on the driver side cornershell of the body. Switch must be turned OFF
when connecting or disconnecting unit to shore power.
Cooling system consists of a condensing unit with one condenser and eutectic cold plates. It operates from
shore power connection, and will run until the eutectic plates are recharged.
Cord box if truck comes with a cord box feature, the line cord can be found in this white box on the driver side
of the truck mounted to the body sub-floor. Cord box cover must be fully closed and latched in order to activate
the ignition cut-out switch, allowing the truck to be started.
Cornershell thermometer is the digital thermometer which allows operator to monitor bodys interior air
temperature only when system is connected to shore power during the pre-cooling process. Located on driver
side front cornershell of the body.
Door strip curtains are flexible vinyl curtains used to reduce air exchange between the refrigerated
compartment and the outside during door openings.
Eutectic cold plates act like the blue ice packs in a picnic cooler and absorb heat to maintain setpoint
temperature levels in the body. When the system is plugged into shore power, refrigerant passes through the
plates recharging the salt brine/eutectic solution after approximately eight hours.
Fahrenheit (F) is a unit of temperature measurement used in the United States and with this refrigeration system.
Fiberglass reinforced plastic (FRP) is a composite material made of a plastic matrix reinforced by fine fibers
made of glass.
Hertz (Hz) is a unit of frequency equal to one cycle per second.
Horsepower (HP) is a unit of power equivalent to 746 watts or 550 foot-pounds per second.
Line cord 25-foot, 30-amp 1-Phase or 3-Phase electrical cord provided inside the cab of the truck to connect
unit to shore power when recharging electric refrigeration system.
Low temperature refrigeration system is designed to maintain the temperature of your product.
Pre-cooling 1) To cool down an empty temperature controlled area to the desired product temperature prior to
loading. 2) To cool product to a desired temperature before loading into the truck body.
Recharging the system is used in reference to plugging the unit into shore power to re-energize the capacity of
the refrigeration cold plates.
Refrigerant is the medium of heat transfer in a refrigeration system which absorbs heat by evaporating at a low
temperature and releases heat by condensing at a higher temperature.
Refrigerant oil is a special oil used to lubricate compressors in refrigerant systems.
Refrigeration is defined as the removal and the relocation of heat.
Shore power also known as dockside power, refers to the electrical power source in which a trucks
refrigeration system can be plugged in and recharged overnight.
Shore power outlet is a standard 3-Phase outlet used to plug refrigeration system into shore power to be
recharged; located on the driver side cornershell.
Volt The basic measuring unit of electrical potential.
Watt The basic measuring unit or electrical power.
- 28 -

WARRANTY
OWNERS WARRANTY RESPONSIBILITES
As the refrigerated truck body owner, you are responsible for the performance of the preventative maintenance
outlined in this Operators 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
MANUFACTURERS WARRENTY WILL BE VOID. TO
OBTAIN PRE-APPROVED AUTHORIZATION
CONTACT JOHNSON TRUCK BODIES AT
800-922-8360

- 29 -

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

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SERVICE RECORD LOG

DATE

MILEAGE

All-Electric Cold Plate System, Low Temp

DESCRIPTION

Manual No. 901-10009

- 31 -

Revision Date: 12/12/2013

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