Side and roof panels – vans, Rear frame, doors and hardware – Great Dane 42101401 User Manual

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SIDE AND ROOF PANELS – VANS

Side and roof panels are critical structural members of
the trailer. Small holes can be patched using an over-
lay panel with blind rivets. Large holes may require
panel replacements. When repairing large holes or
when replacing full panels, use solid rivets of 2117-T4
aluminum for aluminum panels, or solid rivets of type
302HQ for stainless steel panels. Refer to the TTMA
Maintenance Manual.

FIBERGLASS-REINFORCED PLYWOOD (FRP)

FRP panels are of a composite construction where
plywood is overlaid with fiberglass cloth, resins and
gelcoats. It’s very important that any cuts or scrapes
through the outer glass coatings be repaired immedi-
ately to protect against water intrusion into the plywood
core. If the plywood core is exposed to moisture for a
period of time delamination and/or rot may occur.

FRP panel connections to rails, front, and rear frame
connections are sealed with a high-grade sealer at the
time of manufacture. As with any coating or sealer, this
sealer may deteriorate due to age and weathering and
should be inspected and resealed as necessary after
24 months in service.

A Great Dane FRP repair manual is available upon request.

BONDED ROOF

Your equipment should be directed to your qualified
Great Dane branch or dealer repair shop for proper
repairs. If this is not possible, you should contact Great
Dane for proper repair instructions and information on
necessary bonding materials.

REAR FRAME, DOORS
AND HARDWARE

REAR FRAME

The rear frame should be inspected at regular
intervals for damage to the frame, doors and hardware
from impacts with loading docks, abutments or other
devices in the loading area. An area of particular
concern is damage to the rear posts at hinge butts.
This can cause binding, door distortion, and eventual
failure to the door, door hinge, or both.

DOORS

Check rear doors for damage or warpage to panels,
frame or hinges. Compression seals should be
checked to see if the seals need to be repaired or
replaced to ensure a tight closure. The seals around
vent doors, should be checked and maintenance
performed as needed. Interior linings or insulated
doors should be checked for damage or loose or
missing fasteners and repaired as required.

Safety equipment in the rear frame area (such as door
hold backs, grab handles, steps, ramps and slip-resist-
ant materials) should be inspected at TPM. If neces-
sary, they should be repaired or replaced.

HARDWARE

1. Check anti-rack rear door locks for damaged,

distorted, or cracked tubes resulting from impacts.

2. Check operation and engagement of cams into

keepers.

3. Inspect bearing plates for loose or missing fasteners.

4. Check tamperproof fasteners in gravity keepers and

the top and bottom hinge.

5. Check the operation and engagement of the third-

point lock (on some models).

6. On insulated trailers, inspect the interior sealing

surfaces (PVC wedging) to be sure that the thermal
efficiency is maintained. Repair or replace any
components as needed.

OVERHEAD DOORS
If the door becomes difficult or impossible to operate,
have it repaired or adjusted by a qualified mechanic.

1. The door spring is constantly under extreme tension.

Repairs and adjustments, especially to the door
counterbalance assembly, are potentially dangerous
and must be performed by qualified service person-
nel only.

2. Clear any obstruction from the door tracks and the

base of the mounting angle where the door comes
down to the floor.

3. Perform regular inspection and maintenance on the

following items:

a. Be certain that all nuts and bolts are tight and

secure.

b. Check cables full length and at attachment

points and replace all frayed or otherwise
damaged cable.

c. Check cable drums for tightness against

bearings.

WARNING

No attempt should be made to

repair a bond-in-place roof bow/roof sheet
assembly without a complete understanding of
the design, materials and the equipment needed
to achieve the proper repair.

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