Dump Truck Hoist May Fail – 2021-2023 Old Dominion Brush Company DCL1000SE25, DCL800SM30, DCL800SM25, DCL800SM20, DCL800TM30, DCL800TM25, DCL800TM20, & DCL750

SEOCONTENT-START

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 23V-892
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Alamo Group Inc. DEC 22, 2023 NHTSA Recall No. : 23V-892 Manufacturer Recall No. : NR Manufacturer Information :
Manufacturer Name : Alamo Group Inc.
Address : 1627 East Walnut St
Seguin TX 78155
Company phone : (830) 379-1480
Population :
Number of potentially involved : 195 Estimated percentage with defect : 50 %
Vehicle Information : Vehicle 1 : 2021-2023 Old Dominion Brush Compan DCL1000SE25, DCL800SM30, DCL800SM25, DCL800SM20, DCL800TM30, DCL800TM25, DCL800TM20, DCL750
Vehicle Type : BUSES, MEDIUM & HEAVY VEHICLES
Body Style :
Power Train : NR
Descriptive Information : The recall population has been determined based on examination of manufacturing and quality control processes for hoist components in the identified ODB models above. The vehicles in the recall population differ from other vehicles in that the hoist in the recalled ODB vehicles are from a different supplier and may fail if pressure in the hoist exceeds 800 psi.
Production Dates : SEP 01, 2021 – DEC 07, 2023 VIN Range 1 : Begin : 1Z9PS2428NR168323 End : 3BPPHM7X2RF596146 ✔ Not sequential Description of Defect :
Description of the Defect : When the retraction of the hoist that raises and lowers the dump body is blocked or stalled, the bolt connecting the rod and the yoke on the hoist assembly can shear, causing the hoist to fail.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : A hoist failing could cause a dump body to fall and forcefully impact with the chassis, increasing the risk of injury to those in or near the truck or trailer.
Description of the Cause : The design of the hoist does not allow for pressure to exceed 800 psi. The increased pressure buildup (above 800 psi) from suddenly stopping the retraction of the hoist to lower the dump body causes the bolt in the hoist assembly to shear. Identification of Any Warning
that can Occur : Part 573 Safety Recall Report 23V-892 Page 2 Involved Components : Component Name 1 : Hoist
Component Description : Hoist that raises and lowers the dump body of the vehicle Component Part Number : CS628 ODB Supplier Identification : Component Manufacturer
Name : The Godwin Group Address : 200 Champion Dr.
Dunn North Carolina 28334
Country : United States Chronology :
On 11/8/23 ODB was notified by a dealer that during inspection it noticed a bolt connecting the yoke to the cylinder in the hoist assembly on a DCL800 was sheared off. At the time ODB believed this to be an isolated incident due to the incorrect grade of bolt. On 12/7/23 a dealer reported that the same type of bolt in the hoist assembly sheared off a DCL1000 unit, causing the dump body to fall on the chassis. Two persons in the cab of the truck complained of alleged whiplash/concussive injuries. ODB began investigating the issue and on 12/8/23 directed RSMs and its warranty department to tell dealers that all DCL1000s should be put out of service until further notice. That same day a dealer notified ODB that the same type of hoist bolt on an additional unit in for service was also sheared. ODB examined the vehicle that had a hoist failure on 12/7/23 and began investigating the potential cause of these failures. ODB discovered it was due to the buildup of pressure on the bolt in this specific type of hoist when the hoist was retracting and was stalled. ODB then determined which models could have had this type of hoist and isolated them. On 12/14/23 ODB then directed RSMs and its warranty department to tell dealers that all models identified in this report should be put out of service until further notice. On the same day a dealer reported another sheared bolt in the hoist assembly of a DCL1000 while testing/ adjusting a gasket. On 12/20/23, ODB issued a notice directly to affected owners and dealers directing them to put out of service all models identified in this report, due to the suspect hoist. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 23V-892
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
As of 12/22/23, Alamo was aware of no additional warranty claims of field/service reports, no deaths, and no additional injuries (except as stated herein) related to this issue. The aforementioned dealer notifications are the only such notifications. On 12/22/23 Alamo decided to declare a voluntary safety recall to remedy this issue.
Description of Remedy :
Description of Remedy Program : ODB will provide dealers with instructions to examine hoist and, if it is a
Champion hoist, add a pressure relief valve and replace the bolt with a higher grade bolt.
All affected vehicle owners will be notified by first class mail. Affected vehicle owners will be directed to take their vehicle to an ODB affiliated dealer to have the remedy performed free of charge. If this condition was identified and remedied on an affected vehicle prior to this campaign, ODB will reimburse owners who have incurred the cost of such remedy.
How Remedy Component Differs from Recalled Component : Identify How/When Recall Condition was Corrected in Production :
The remedy provides for the reduction of pressure on the hoist and additional support with a higher-grade bolt. This will keep the hoist from failing and the dump body from unexpectedly lowering
December 8, 2023, ODB has changed its manufacturing process to include the pressure relief valve and higher-grade bolt. Recall Schedule :
Description of Recall Schedule : ODB will notify all owners and dealers of affected vehicles by Part 577-
compliant owner letters sent via USPS within 60 days. Concurrent with filing the 573 report to notify NHTSA, ODB will send a TSB to all owners and dealers of affected vehicles with direction to put vehicles out of service and instructions to perform the recall remedy.
Planned Dealer Notification Date : FEB 20, 2024 – FEB 20, 2024
Planned Owner Notification Date : FEB 20, 2024 – FEB 20, 2024
* NR – Not Reported

**************************************************************************************************************

Instructions
1 TSB112119
Technical Service Bulletin TSB 120823 Rev3 January 2nd, 2024
Your truck/trailer may be equipped with a hoist that requires prompt servicing, in accordance with this TSB, to prevent premature hoist failure. This TSB will help you identify whether your truck/trailer must have this remedy performed. If your truck/trailer is within the affected population, please promptly perform the remedy described in this TSB. REMOVE UNITS FROM SERVICE IMMEDIATELY Do not operate any dump functions until this TSB has been completed.
Subject:
Champion Hoist Relief Valve Installation
Affected Products:
DCL1000SE25, DCL800SM20, DCL800M25, DCL800SM30, DCL800TM25, DCL800TM30, DCL800TM20, DCL800TM25, DCL800TM30, DCL750TM25
Affected Product Range:
All units with the Champion hoist installed
Remedy Required:
A relief valve is required on the retract side of the hoist to prevent premature hoist failure.
Affected Unit Identification
How to identify if your unit is affected:
Use the flowchart and tables below to determine whether your unit is affected. Fill in the information below for each unit and return a copy of this sheet to ODB.
Serial Number
Model
Hoist Type
Valve Type
Signed: ________________________________
Printed Name: __________________________
Date: _________________________________
Instructions
2 TSB112119
Flowchart to identify whether your truck/trailer must be remedied:
Instructions
3 TSB112119
Hoist Identification: Check Champion Hoist Crysteel Hoist
Cylinder nameplate (located on the side of the mechanism)
Rear end of hoist (nearest box hinge)
The end of the Champion hoist is round on the bottom.
The Crysteel hoist is angular on the bottom.
Hoist mounting points
The Champion hoist mounting point is triangular. The body prop is separate from the hoist mount.
The Crysteel mount point is rectangular. The body prop is integrated into the hoist mount.
Instructions
4 TSB112119
Valve Identification: Valve Picture
Aluminum block
1-section manual
Eco 80
2-section manual
Instructions
5 TSB112119
Parts Required: Part Number Qty Description
2925XZ
1
KIT,HOIST RELIEF
2926XZ
1
VALVE,INLINE,RELIEF
2927XZ
1
PLT,RELIEF VALVE MOUNT
2928XZ
1
BOLT,CHAMPION HOIST CYLINDER
2929XZ
1
HYD,FITTING,8 R5OX
2930XZ
1
HYD,FITTING,8 S5OX
2933XZ
2
HYD,FITTING,8 C6X
2934XZ
1
LINE BODY,2 WAY,SLOT MOUNTS
2936XZ
1
HOSE,DUMP,EXTEND WHIP
2937XZ
1
HOSE,DUMP,RETRACT WHIP
2941XZ
1
PLT,BOX,COVER FOR DRILLED HOLE
2942XZ
1
DECAL,DO NOT CHANGE RELIEF
1
5/8” nylock nut
2
M8 x 30 mm bolts
2
¼” x 2” bolts
6
¼” x 1-1/4” bolts
16
¼” flat washers
8
¼” nylock nuts
4
¼” sheet metal screws
4
?” rivets
Tools Required:
•
Drill
•
5/16” drill bit
•
Torque wrench (35-40 ft-lbs/47-54 Nm capable)
•
Open-end wrenches
•
Ratchet wrench
•
Sockets
•
Hex wrenches
•
Oil drip pan
•
Oil-absorbent pads
•
Tape measure
•
2” hole saw
•
46W hydraulic oil (around 2 gallons)
Instructions
6 TSB112119
Actions Required:
Before performing any service, always follow applicable safety precautions. Consult company safety manual or supervisor for questions concerning safety. If your unit has a Crysteel hoist, the aluminum block valve, or the 1-section manual valve, as determined above, it may return to service at this time.
WARNING DO NOT ACTUATE DUMP TO ACCESS HOIST Hoists with a broken bolt may lower the box suddenly and without warning, leading to injury or death.
Install relief kit:
1.
Ensure the box is lowered completely. Lower the box with a crane or fork lift if the box is stuck up for any reason.
2.
Clean any debris off the control valve. Allow the valve to dry completely.
3.
Mount the relief valve and bracket (2926XZ, 2927XZ, 2929XZ, 2930XZ, 2933XZ, 2934XZ) to the machine, between the control valve and the hoist cylinder. Refer to the following table for location based on model.
Model Install Location Installation Notes Picture
DCL1000
To the left of the valve, when looking from the side of the machine.
The bracket shares the two rear bolts securing the valve. Only the holes closest to the relief valve will be used.
Replace the two M8 bolts that the valve bracket will mount to with the M8 x 30 bolts in this kit.
Instructions
7 TSB112119
Model Install Location Installation Notes Picture
DCL800SM
To the right of the valve, when looking towards the rear of the machine.
The bracket attaches to two holes on the front of the skid. Only the holes on the short flange will be used.
DCL800TM
On the left side of the valve bracket, when looking from the tongue.
Match drill (2) 5/16” holes in the left side of the existing bracket for the relief bracket.
DCL750
On the left side of the valve bracket, when looking from the tongue.
Match drill (2) 5/16” holes in the left side of the existing bracket for the relief bracket.
Instructions
8 TSB112119
4.
Apply the decal (2942XZ) to the long flange on the top of the bracket.
The Eco 80 control valve, as seen from the wire side. The dump section is on the far left. Verify hose routing before proceeding.
5.
Identify the dump up and dump down hoses by tracing them back from the cylinder. Mark each hose to indicate which side of the cylinder it is connected to.
6.
With the truck and auxiliary engine off (if applicable), release hydraulic pressure from the dump section by manually actuating the dump section of the valve (found in Step 4) in both directions. Hold the lever fully in each direction for at least 10 seconds to ensure that all pressure has been relieved from the hoses.
a.
For the Eco 80 valve, install a valve handle or use a 9 mm wrench to manually actuate the valve.
7.
Install a drip pan beneath the control valve to catch oil.
8.
Remove the dump hoses from the valve. Slide the hoses away from the valve through the zip ties so the fittings are closer to the relief valve.
Instructions
9 TSB112119
The relief valve, with fittings. The fittings on the right are the “UP” side and is stamped with a 2; the fittings on the bottom are the “DOWN” side and is stamped with a 1.
9.
Install the dump up (extend) hose to the tee fitting on the side of the valve marked “UP.”
10.
Install the dump down (retract) hose to the tee fitting on the side of the valve marked “DOWN.”
11.
Install the dump up hose jumper (2931XZ) from the tee fitting on the side of the valve marked “UP” to the control valve and install on the port that the dump up hose was removed from.
UP
DOWN
Instructions
10 TSB112119
12.
Install the dump down hose jumper (2932XZ) from the tee fitting on the side of the valve marked “DOWN” to the control valve and install on the port that the dump down hose was removed from.
13.
Slide any loose hose loops back into the skid and secure away from any moving parts.
Instructions
11 TSB112119
14.
Remove the bolt connecting the cylinder to the hoist mechanism. Discard the nut and bolt. WARNING Do not reuse the existing bolt. Using a damaged bolt could cause the hoist to fail, causing injury or death. Even if the bolt appears to not be damaged, it could fail.
WARNING Do not reuse the existing nylock nut. Extended use or repeated installations of nylock nuts can cause the nylon locking mechanism to loosen, reducing the security of the joint.
15.
Replace the bolt and nut connecting the cylinder to the hoist mechanism (2928XZ). Torque the nut to 106 ft-lbs (lubricated) or 212 ft-lbs (non-lubricated).
a.
It may be necessary to cut a hole in the box to access the top of the hoist and install the bolt. Cut a 2” hole in the floor of the box.
Instructions
12 TSB112119
Hole dimensions. The rear of the box is down. The door is not shown.
i.
For the DCL1000SE25, the hole should be 68” from the rear sill of the box and 33” from the curb side wall of the box.
b.
Use the patch plate (2941XZ) to cover hole after bolt has been replaced. Secure the patch plate with sheet metal screws, bolts or rivets.
16.
Ensure proper oil level and bleed air from all hoses by following TSB101322 DCL1000 Oil Fill.
17.
Properly dispose of any oil and oil-soaked rags.
Supplemental Materials
13 TSB112119
Valve Body and Fitting Installation
General Arrangement:
Clamp the body in a vise, with the valve port facing up. The valve port has a dot next to it.
Install valve cartridge with a 1 in wrench and torque to 35-40 ft-lbs (47-54 Nm).
35-40 ft-lbs
Supplemental Materials
14 TSB112119
Mark the valve body and cartridge with a line of cross check or a paint pen.
Loosen the adjustment jam nut with a 3/4 in wrench and unscrew the adjustment screw with a 3/16 in hex wrench until it stops.
Turn the adjustment screw in 3 full turns. Tighten the jam nut while holding the adjustment screw.
3 turns
Supplemental Materials
15 TSB112119
Mark the cartridge threads and body with a line of cross check or a paint pen.
Thread the branch tee in to the port marked 1.
Thread the run tee in to the port marked 2.
1
2
Supplemental Materials
16 TSB112119
Thread the 90-degree fittings on the right sides of the tees.
Angle the side ports (tees and 90s) 30 degrees up.
Tighten all fittings, holding each fitting as it is tightened to maintain the angles.
30°

**************************************************************************************************************

**************************************************************************************************************

SEOCONTENT-END