SN719 – Aerial Device Subframe Improperly Welded – 2021 Terex TL48 Trucks

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OMB Control No.: 2127-0004 Part 573 Safety Recall Report 23V-396 The information contained in this report was submitted pursuant to 49 CFR §573 Manufacturer Name : Terex South Dakota, Inc. Submission Date : JUN 02, 2023 NHTSA Recall No. : 23V-396 Manufacturer Recall No. : SN719 Manufacturer Information : Manufacturer Name : Terex South Dakota, Inc. Address : 3140 15th Ave SE PO Box 1050 Watertown SD 57201 Company phone : 18448373948 Population : Number of potentially involved : 8 Estimated percentage with defect : 100 % Vehicle Information : Vehicle 1 : 2021-2021 Terex TL48 Vehicle Type : LOW VOLUME VEHICLES Body Style : Power Train : NR Descriptive Information : The population includes all TL48 machines built from February 4, 2021 to September 30, 2021. Production Dates : FEB 04, 2021 – SEP 30, 2021 VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect : Description of the Defect : There are 8 threaded insert tubes that are welded into the subframe for the purpose of bolting the aerial device to the subframe. The welds for the insert tubes may not have been properly performed resulting in insufficient strength to hold the insert tubes in place. FMVSS 1 : NR FMVSS 2 : NR Description of the Safety Risk : If the welds fail the aerial device could fall which could result in injury or death. Description of the Cause : The weld joint was improperly welded. Identification of Any Warning that can Occur : Daily visual inspection may indicate the presence of cracks in the welds. There may be excessive movement of the turntable when the welds have failed. Involved Components : Part 573 Safety Recall Report 23V-396 Page 2 The information contained in this report was submitted pursuant to 49 CFR §573 Component Name 1 : Subframe Weldment, 123.00″ LG Component Description : Sub-base for the TL48 aerial device Component Part Number : 625726 Supplier Identification : Component Manufacturer Name : Central Plains Industries Address : 42989 US Highway 212 Clark South Dakota 57225 Country : United States Chronology : On November 23, 2021 it was discovered on a Terex test unit that the subframe insert welds had failed. Analysis of the failed subframe showed inadequate welds attaching the insert tubes into the subframe. On November 29, 2021, a subframe was pulled from inventory and the welds inspected which also showed inadequate weld penetration attaching the insert tubes into the subframe. On November 30, 2021 all in stock and in process subframes of part number 625726 were identified and rework began. Development of a potential field fix began on December 2, 2021. Validation of the field fix was completed on May 23, 2023. Even though there are no reports of issues, a decision to recall was made on June 1, 2023. Description of Remedy : Description of Remedy Program : All affected subframes are to be inspected for cracking. The insert welds on the top side of the subframe are to be removed and the joint rewelded at no cost to the customer. How Remedy Component Differs from Recalled Component : No visible distinguishing characteristics. Identify How/When Recall Condition was Corrected in Production : On December 15, 2021 the weld joint design was changed. The subframe manufacturer provided weld samples for analysis to determine that the weld met the design requirements. A completed subframe with the design changes was randomly selected, sectioned, and analyzed to determine if the welds met the design requirements. Recall Schedule : Part 573 Safety Recall Report 23V-396 Page 3 The information contained in this report was submitted pursuant to 49 CFR §573 Description of Recall Schedule : Dealer notification will begin by June 8, 2023. Owner notification will begin by July 14, 2023. Planned Dealer Notification Date : JUN 08, 2023 – NR Planned Owner Notification Date : JUL 14, 2023 – NR * NR – Not Reported

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1 Kolden, Les From: Kolden, Les Sent: Thursday, June 8, 2023 10:33 AM To: James Matlock; John Pittman; Karen Moore; Mike Cannon; Renee Mizell; Shawn Willis Cc: Ries, Craig; Hegstrom, Jeff Subject: Defect Information Report filed with NHTSA for upcoming SN719 Attachments: Safety Notice 719 – NHTSA# 23V396 Defect Information Report.pdf Good morning, We wanted to make you aware of the attached Defect Information Report that was filed with the National Highway Transportation Safety Administration (NHTSA). NHTSA has assigned their bulletin# 23V396 to this report. As yet, NHTSA has not posted this report to their website. The repair procedure and repair kit and being worked on right now. If you get a call about this report, you can speak with the customer but we ask that you don’t forward any information as it will be available on the NHTSA website. The first owner letter mailing will take place no later than July 14, 2023. Please call me if you have any specific questions or concerns. Regards, Les K Les Kolden Product Support Coordinator Terex Utilities 3140 15th Ave SE Watertown, SD 57201 T +1 605.882.5595 F +1 605.882.1842 E [email protected]

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Terex South Dakota, Inc. 3140 15th Ave SE Watertown, SD 57201 USA 1-844-837-3948 • Fax 1-605-882-1842 Terex Utilities SAFETY NOTICE SN719 DATE: 6/21/2023 REVISED: TO: Owners, Users, Dealers, and Installers MODELS AFFECTED: TL48 SUBJECT: Subframe Insert Welds Issue: Terex TL48 model aerial devices, produced from February 2021 through September 2021, may have subframe weld issues. The welds for the threaded inserts that the aerial device mount to may crack loose from the surrounding subframe material. Failure of the subframe welds could cause the boom to separate from the truck frame which could result in injury or death. Action: What the Owner Must Do: The owner must inspect their equipment and correct if required: 1. Immediately inform all users, operators, and supervisors that the bottom side of the subframe where the aerial device mounts must be visually inspected before further use. 2. Inspect to determine if welds are cracked for the threaded inserts using the figures below as reference. Figure 1. Area of subframe to inspect 8 welds to inspect 2 Figure 2. Weld to inspect 3. If no cracks are detected during the visual inspection the unit can be used following the instructions in the continued use section in this bulletin as well as all operator, maintenance, and inspection requirements as specified in the manuals. 4. If cracking is detected in the welds, do not use the machine and contact Terex Utilities Warranty Department using the contact information in this bulletin. Continued Use: Inform the users of the content of this bulletin and remind them of the daily pre-shift inspection requirements. 1. Conduct a weekly inspection of the bottom side of the subframe for cracked welds around the threaded inserts using the figures above as reference until Field Service Kit Z1650 is completed. a. If no cracking is detected in the welds machine use can continue until Field Service Kit Z1650 is completed, following all operator, maintenance, and inspection requirements as specified in the manuals and this bulletin. b. If cracking is detected in the welds, do not use the machine and contact Terex Utilities Warranty Department using the contact information in this bulletin. 2. Continue with the weekly visual inspection until Field Service Kit Z1650 is completed. 3. Within 10 days of receiving this bulletin contact Terex Utilities; through your nearest Terex Utilities dealer as shown on the web site, terexutilities.com, call Terex Utilities Warranty Department at 1-844-837-3948 or by email at [email protected] to arrange for repair. 4. Always follow inspection and maintenance requirements as specified in the manuals. What Terex will Do: Terex will complete Field Service Kit Z1650 at no cost to the customer. The Field Service Kit Z1650 provides instructions for removing the welds for the threaded inserts at the top of the subframe and to reweld the top side of the inserts to the subframe tubes. Contact Terex Utilities; through your nearest Terex Utilities dealer as shown on the web site, terexutilities.com, call Terex Utilities Warranty Department at 1-844-837-3948 or by email at [email protected] to arrange for repair within 10 days of receiving this bulletin. If you have sold the unit involved in this bulletin forward this bulletin to the new owner within 10 days and notify Terex of the serial number and contact information for the new owner. Dealers and Installers: A letter is being sent to owners of affected units. If affected units are in your area, Terex Utilities will contact you to arrange the repairs. Inform owners it will take approximately 8 hours to complete the repair. Inspect this weld for cracks 3 Only TL48 models manufactured in the time frame specified in this bulletin are involved. If the owner contacts you, call Terex Utilities Warranty Department at 1-844-837-3948 for instructions and to arrange for repair of their machine. Affected units, as shown on the owner letter, will have the repairs performed at no charge to the owner. Important: Some of the involved units may be in rental fleets. Federal Law requires you to complete the recall service on these units before renting, or to inform the renters within 10 days of receipt of this bulletin. Note to Owners: If the manufacturer or their dealer has failed or is unable to remedy the defect/noncompliance condition without charge or within a reasonable amount of time you can notify: Administrator National Highway Traffic Safety Administration 1200 New Jersey Avenue, SE, West Building Washington, DC 20590 Or call the toll-free DOT auto Safety Hotline at 1-888-327-4236 (TTY: 1-800-424-9153; or go to http://www.safercar.gov .) Terex and local industry standards (CSA and ANSI) require the purchaser of a Terex unit report to Terex the model and serial number of each machine sold, as well as the name, address, and telephone number of the new owner, within 60 days of the sale. Use the Owner Update Form in the manual to update the owner status of any of your machines. Terex also asks the seller to provide the new owner information so if you require additional copies of the Owner Update Form or have any questions, please contact Terex Utilities Warranty Department at 1-844-837-3948 or [email protected]. Terex, OSHA and local industry standards, also require that the manufacturer’s bulletins be completed. It is your responsibility to communicate this important information to all machine owners and applicable branches. If you require additional copies of this bulletin or have any questions, please contact Terex Utilities at 1-844-837-3948. To register your Terex Utilities aerial device or digger derrick, click or navigate to the following link: https://www.terex.com/utilities/en/support/product-registration

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