Hydraulic Cylinder Attachment Bolts May Fail – 2020-2021 PJ Trailers DE Trailers

August 28, 2020 NHTSA CAMPAIGN NUMBER: 20V522000

Hydraulic Cylinder Attachment Bolts May Fail

Use of the dump box after the attachment bolts fail may result in a sudden drop of the box as it is being raised, increasing the risk of injury.

 

NHTSA Campaign Number: 20V522

Manufacturer PJ Trailers

Components EQUIPMENT

Potential Number of Units Affected 694

 

Summary

PJ Trailers is recalling certain 2020-2021 DE trailers. The attachment bolts of the hydraulic cylinder may fail if the hydraulic system is used to lower the dump box once the dump box is already in the fully lowered position.

 

Remedy

PJ Trailers will notify owners, and dealers will replace the hydraulic power unit and the attachment bolts, free of charge. The recall began October 2, 2020. Owners may contact PJ Trailers customer service at 1-866-752-8781.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.safercar.gov.

 

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IMPORTANT SAFETY RECALL

#20V522

 

Date:	September 25, 2020
To:	All American Trailer Connection
Subject:	Safety Recall Campaign
Involving:	2020-2021 PJ Trailers Model DE Dump Trailers

 

PJ Trailers Manufacturing, Inc. (PJ Trailers), has decided that a defect, which relates to motor vehicle safety, exists in the certain 2020-2021 PJ Trailers Model DE Dump Trailers. During the normal operation of the dump trailer, when lowering the dump box, the secondary hydraulic relief pressure is set at 1,500 psi. When the dump box is in the fully lowered position, if the consumer continues to engage the hydraulic system, the remaining stroke of the cylinder pulls the box into the frame of the trailer, which can cause the attachment bolts of the hydraulic cylinder to fail. If the hydraulic cylinder attachment bolts fail and go undetected, the hydraulic cylinder can become separated from the lifting assembly. Should the hydraulic cylinder separate from the lifting assembly, the next time the cylinder is used, it could result in the failure of the box to raise or the sudden drop of the box as it is being raised. A failure of the hydraulic cylinder attachment bolts could result in accidental damage to include personal injury, death and/or property damage.

 

Owners will be notified by mail about the recall and will be instructed to contact PJ Trailers to schedule the required repair. There is no cost to owners for this recall. Dealer should immediately notify PJ Trailers of the name and address of each person or entity to whom the Dealer has sold or delivered one of the affected trailers.

 

Important: Some of the involved trailers may still be in your inventory. Enclosed as Attachment 1 is a listing of the affected trailers identified by VIN that our records indicate were shipped to you. Please provide purchaser information for each trailer and provide that information to PJ Trailers Manufacturing, Inc. as soon as possible. The requested information should be directed to PJ Trailers Manufacturing, Inc., ATTN: Recall Office, via mail to 1807 FM 2352, Sumner, Texas 75486; via fax to (903) 785- 6898, or via email to recall@pjtrailers.com Federal law requires you to complete the recall service on those trailers still in your inventory before retail delivery.

 

Repair affected trailers as they are brought into your dealership. Contact PJ Trailers’ warranty department should you have any questions regarding the repair at recall@pitrailer.com or toll free at 888-330-8106.

 

Instructions regarding the replacement of the hydraulic power unit and hydraulic cylinder attachment bolts are outlined in the attached Service Alert Bulletin.

 

You are being provided with a Repair Confirmation Form, which·you are requested to complete for each hydraulic power unit and hydraulic cylinder attachment bolt replacement you complete. Upon completion of the necessary replacements, you are required to return the completed Repair Confirmation Form to PJ Trailers Manufacturing, Inc. via facsimile to 903-785-6898 or via email to recall@pjtrailers.com, and upon receipt of the completed Repair Confirmation Form to PJ Trailers, you will be reimbursed for the repairs performed. PJ Trailers estimates it will take approximately 2 hours to complete the necessary repair.

 

Additionally, please·return the hydraulic power unit for any unsold trailer that was removed from the affected trailer to PJ Trailers at 1807 FM 2352, Sumner, Texas 75486. Please contact PJ Trailers for shipping information. All return shipping expenses will be paid for / reimbursed to you by PJ Trailers upon receipt of the returned hydraulic power unit.

 

Please be reminded that it is a violation of Federal law for you to sell or lease any of the affected trailers covered by this notification until this recall has been performed on the affected trailer.  Substantial civil penalties apply to violations of this law.

 

If you have questions concerning this recall, please contact the PJ Trailers Warranty department at recall@pjtrailers.com or at 888-330-8106.

 

Your immediate assistance in this important effort is appreciated. PJ Trailers Manufacturing, Inc.

 

SERVICE ALERT BULLETIN: Power Unit Exchange & Hydraulic Cylinder Bolt Replacement
SCOPE	Model: DE Year: 2020, 2021
PURPOSE	To exchange Power Unit with new model and replace bolts securing hydraulic cylinder to hoist.
REQUIRED TOOLS & COMPONENTS	Specified in Each Section

 

REPAIR KIT #1

• Power Unit (SN: DC 45327)

• (2x) 1/2″ x 2-1/2″ Grade 8 Bolt

• (lx) 5/8″ x 4″ Grade 8 Bolt

• (2x) 5/8″ x 1/4″ Thick Flat Washer

• (2x) 4′ Safety Props

 

REPAIR KIT #2

• Power Unit (SN: DC 45328)

• (2x) 1/2″ x 2-1/2″ Grade 8 Bolt

• (1x) 5/8″ x 4″ Grade 8 Bolt

• (2x) 5/8″ x 1/4″ Thick Flat Washer

• (2x) 4′ Safety Props

 

Pump Box Components

 

Pump Box

 

Battery

 

TOP VIEW

 

Power Unit (contains reservoir and pump)

Controller

 

REQUIRED TOOLS & COMPONENTS

• 1/2″ Wrench

• 9/16″ Wrench

• 11/ 16″ Wrench

• Sharpie Marker

• Shop Rags

• Eye Protection

• Fluid Funnel

• New Power Unit

• Chevron Hydraulic Oil AW

 

REPAIR PREP

1) Position trailer on level ground. Dump bed in fully lowered position.

2) Chock wheels to prevent trailer movement.

3) Jack trailer to level position. Trailers with power lift should be lowered on blocks to prevent unintended movement.

4) Remove negative battery cable from battery.

5) Remove positive battery cable from battery.

 

REPAIR STEPS

1) Remove positive battery cable from Power Unit.

2) Remove negative battery cable from Power Unit.

3) Disconnect Pendant Controller.

4) Mark a “T” on top hydraulic line with sharpie to ensure proper reconnection.

5) Place shop rags in bottom of box to catch any fluid spill.

6) Slowly disconnect top hydraulic line with 11/16″ wrench to let pressure bleed out.

 

WARNING: Hydraulic line is under pressure. Disconnecting the line too fast can cause a burst of hydraulic fluid.

Proceed with caution.

 

7) Slowly disconnect the bottom hydraulic line with 11/16″ wrench to let pressure bleed out.

WARNING: Hydraulic line is under press_ure. Disconnecting the line too fast can cause a burst of hydraulic fluid.

Proceed with caution.

 

8) From the underside of the box, remove the bolt that secures Power Unit to the box with 9/16″ wrench or socket. Save for reinstallation.

9)   Carefully remove old Power Unit from box.

10)   Remove two 90° fittings from Power Unit with 11/16″ wrench, save for reinstallation.

11)   Clean up excess hydraulic fluid with shop rag and dispose according to local environmental guidelines.

12) Install 90° fittings to new Power Unit. Fitting opening should face motor end of unit. Screw fitting in by hand and tighten retaining nut with 11/16″ wrench. Do not over tighten.

13) Confirm new Power Unit serial number is either DC 45327 or DC 45328. Carefully place new Power unit into box and secure with two bolts from underside of Tighten with 9/16″ wrench or socket.

14) Connect bottom hydraulic line to new Power Unit with 11/16″ wrench, fully Then connect the top hydraulic line marked with ” T ” and fully tighten as well.

15) Connect negative battery cable to new Power Unit, do not attach to battery.

16) Connect positive battery cable to new Power unit, do not attach to battery.

17) Connect positive battery cable to battery.

18) Connect negative battery cable to battery.

19) Using a fluid funnel, refill hydraulic fluid reservoir to the FULL line on the side of the tank with Chevron Hydraulic Oil AW.

20) Connect Pendant Controller to Power Unit.

 

HYDRAULIC CYLINDER BOLT REPLACEMENT

 

REQUIRED TOOLS & COMPONENTS

• Two 4′ Safety Props

• 1/2″ Wrench

• 3/4″ Socket Wrench

• Fire Resistant Blanket

• Two 1/2″ x 2.5″ Grade 8 Bolts

• One 5/8″ x 4″ Grade 8 Bolt

• Two 5/8″ x 1/4″ Thick Washers

• Welding Torch

• Chevron Hydraulic Oil AW

• Eye Protection

 

REPAIR PREP

1) Repeat Steps 1-3 from Power Unit Exchange Repair Prep to prevent trailer movement.

2) Raise dump bed·,then lower onto supplied 4′ safety props, one on each side. Safety props must be secured by placing each end over a crossmember, one on the trailer frame and one on the bed subframe.

 

WARNING: Hoist cylinder does not prevent dump bed from lowering. Ensure safety props are secure before working under dump bed.

Proceed with caution.

 

3) Remove negative battery cable from battery.

 

REPAIR STEPS

1) Locate hoist hydraulic cylinder bottom connection point that attaches to trailer frame.

2) Remove one bolt from cylinder connection with 3/4″ socket wrench.

3) Replace with 1/2″ x 5″ Grade 8 Bolt and fully tighten.

4) Repeat steps 2 & 3 for the second bolt.

 

WARNING: Do not remove more than one bolt at a time to prevent the cylinder from unintended movement.

5) Locate hoist hydraulic cylinder top connection point that attaches to hoist.

6) Place fire resistant blanket around hydraulic cylinder shaft for protection.

7) Remove bolt & washer.

8) Inspect hole for any elongation. If no elongation of the hole is found, replace with new bolt and skip to Step If elongation is present, proceed with Step 9.

9) Grind surface around elongated hole in preparation for welding Repeat on opposite side.

10) Place new 5/8″ x 4″ Grade 8 Bolt into the hole with a 5/8″xl/4″ thick washer on both Secure with 5/8″ nut.

11) Fully weld outer edge of both washers to the tube.

12) Remove fire resistant blanket from the hydraulic shaft.

13) Clear area underneath dump bed of all tools and personnel.

14) After Step 13 is complete, reconnect negative battery terminal to restore power to the Raise dump bed, carefully remove safety props, and fully lower dump bed.

15) Fully cycle dump bed up and down three times to remove excess air and ensure proper

 

NOTE: If hydraulic fluid in tank drops below MIN line, refill tank to FULL line.

 

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IMPORTANT SAFETY RECALL

This notice applies to your equipment,

Serial Number

 

Date: October 2, 2020

Safety Recall Number: 20V522

 

Dear

 

This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act.

 

PJ Trailers Manufacturing, Inc. (PJ Trailers), has decided that a defect, which relates to motor vehicle safety, exists in the certain 2020-2021 PJ Trailers Model DE Dump Trailers. During the normal operation of the dump trailer, when lowering the dump box, the secondary hydraulic relief pressure is set at 1,500 psi. When the dump box is in the fully lowered position, if the consumer continues to engage the hydraulic system, the remaining stroke of the cylinder pulls the box into the frame of the trailer, which can cause the attachment bolts of the hydraulic cylinder to fail. If the hydraulic cylinder attachment bolts fail and go undetected, the hydraulic cylinder can become separated from the lifting assembly. Should the hydraulic cylinder separate from the lifting assembly, the next time the cylinder is used, it could result in the failure of the box to raise or the sudden drop of the box as it is being raised. A failure of the hydraulic cylinder attachment bolts could result in accidental damage to include personal injury, death and/or property damage.

 

Your trailer has been identified as included in this recall. You are advised not to use the trailer for any purpose and to immediately contact PJ Trailers to schedule the required repair. Please contact PJ Trailers Warranty at 888-330-8106 or recall@pitrailers.com immediately to schedule a repair.

 

The defect will be remedied by your authorized PJ Trailers dealer or representative, who will replace the hydraulic power unit and hydraulic cylinder attachment bolts. The work will take about 2 hours to complete. However, additional time may be required depending on how dealer appointments are scheduled and processed. To make the appointment to schedule the necessary hydraulic cylinder and hydraulic cylinder attachment bolt repair, which will be performed at no charge to you, please do the following:

 

Call PJ Trailers Manufacturing, Inc. toll free at 888-330-8106 or contact via email at recall@pitrailers.com for the location of your closest PJ Trailers dealer, or authorized representative, who will perform the repair. You should call the same number if you have any problem obtaining the needed repair, DO NOT USE THE TRAILER FOR ANY PURPOSE.

 

If you had this repair performed before you received this letter, you may be eligible to receive reimbursement for the cost of obtaining a pre-notification remedy of the problem associated with this recall. For more information contact PJ Trailers at 888-330-8106 or by email to recall@pitrailers.com.

 

Upon completion of the necessary repair, the dealer or PJ Trailers authorized representative will notify PJ Trailers Manufacturing, Inc. that your trailer has been repaired.

 

If you no longer own the subject trailer, please provide PJ Trailers with the new owner’s information (if known), either by mail to the address listed above, by email to recall@pitrailers.com or by fax to (903) 785-6898, If the new owner information is unknown, simply notify PJ Trailers that you no longer own the subject trailer.

 

If you believe that PJ Trailers Manufacturing, Inc. has failed or is unable to remedy the defect without charge within a reasonable time, you may submit a complaint to:

Administrator
National Highway Traffic Safety Administration
1200 New Jersey Avenue, S.E.
Washington, DC 20590

or call the toll-free Vehicle
safety Hotline at 1-888-327-4236
(TTY: 1-800-424-9153); or go to
http:/ www.safercar.gov

 

Federal regulations require that any vehicle lessor receiving this recall notice must forward a copy of this notice to the lessee within ten days,

 

We regret any inconvenience, which this action may cause you, This program is being carried out to ensure your safety.

 

Your prompt attention to this important matter is appreciated.

Sincerely, PJ Trailers Manufacturing, Inc.

 

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2 Affected Products

Vehicle

MAKE	MODEL	YEAR
PJ TRAILERS	DE	2020-2021

 

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8 Associated Documents

Recall Quarterly Report #3, 2021-2

RCLQRT-20V522-3962.PDF 211.298KB

 

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Recall Quarterly Report #2, 2021-1

RCLQRT-20V522-7431.PDF 211.214KB

 

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Recall Quarterly Report #1, 2020-4

RCLQRT-20V522-8648.PDF 211.214KB

 

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Owner Notification Letter(Part 577)

RCONL-20V522-8177.pdf 1685.358KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-20V522-0521.pdf 15121.648KB

 

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Recall 573 Report

RCLRPT-20V522-5723.PDF 214.303KB

 

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Recall Acknowledgement

RCAK-20V522-3382.pdf 244.494KB

 

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Recall Quarterly Report #4, 2021-3

RCLQRT-20V522-7651.PDF 211.399KB

 

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Latest Recalls Documents

For the Latest and Most Recent Recalls Information Visit the link below…

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V522&docType=RCL

 

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