2021 Jayco Travel Trailer Jay Flight Slx

We bought a 2021 Jayco 224BHW that was pre-wired with a solar panel and controller. The trailer came with one 100-watt panel and a 30-amp charge controller with a stated capacity of 600 watts. We added two more 100-watt panels, for a total of 300 watts and approximately 16 amps. The documentation with the trailer as well as the dealer confirmed we could add two more 100-watt panels and be well within specifications. After utilizing the system for a few months the solar suddenly worked sporadically and then ceased too function. Upon inspection under the roof port entry it was discovered Jayco had utilized wire nuts between a transition from the roof port and the wire run to the solar controller. The wire nuts failed to adequately make or maintain the connection, resulting in arcing, melting, and burning of the surrounding insulation. It could easily have resulted in loss of the trailer or our lives to fire. I believe the wire nuts were either inadequately sized, improperly installed, or inappropriate for use in a structure that is subject to vibration and loosening of the connections.

Component: Electrical wiring on the slide is contacting edge of trailer flashing when fully retracted into trailer. In the attached photos you can see where the flashing has contacted the wire loom numerous times, you can see indentations in the cable jacket, and you can see that the flashing is slightly bent where making contact. The flashing is installed to be flush with the surface on the other side of the cables. There is no room for the cables how its constructed. Safety: Flashing can continue to rub/cut against cable jacket causing potential electrical safety hazard. Confirmation: This was made aware to me by another owner of the same make, model, and year trailer who's damage was more severe. Inspected: No Warning/Symptoms: No

– Electrical fire is possible at the wiring (12V and 110V) connecting the slide out room to the main trailer body. Closing the slide is jamming the wires between two metal flaps resulting in wire jacket damage and exposing the wires under power. – The 110V hot wire was damaged by another part mounted to the trailer frame resulting in shortening hot wire to the frame, spark and burning of electrical wire in she short proximity of combustible underbelly insulation material. – The dealer has not been contacted. – The vehicle was not inspected. – The issue appeared as a sparking under the left trailer wheel pair when connecting to the shore power at the campsite. Prior to the incident, the metal flap cut through the cable insulation and shortened the hot wire to the frame. There was no any indication of this issue prior to the incident.