SN724 – Boom Rotation Bearing Bolts Not Tightened Properly – 2023 Terex Optima-TC55, Optima-HRX50, Optima-HRX55, & XT Pro

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 24V-042
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Submission Date :
Terex South Dakota, Inc. JAN 25, 2024 NHTSA Recall No. : 24V-042 Manufacturer Recall No. : SN724 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 : 340 Estimated percentage with defect : 90 %
Vehicle Information : Vehicle 1 : 2023-2023 Terex Optima-TC55, Optima-HRX50, Optima-HRX55, XT Pro Vehicle Type : LOW VOLUME VEHICLES
Body Style :
Power Train : NR
Descriptive Information : The quality records for the affected product lines were used to determine the recall population. All XT Pro aerial devices produced from May 2, 2023 through July 11, 2023 and Optima-TC55, Optima-HRX50, and Optima-HRX55 aerial devices produced from August 28, 2023 through October 5, 2023 are included in the recall population.
Production Dates : MAY 02, 2023 – OCT 05, 2023
VIN Range 1 : Begin : NR End : NR Not sequential Description of Defect :
Description of the Defect : The turntable to rotation bearing bolts may not have been torqued properly.
The improperly torqued bolts may loosen causing the bearing bolts to fail.
FMVSS 1 : NR FMVSS 2 : NR
Description of the Safety Risk : Failure of the rotation bearing bolts could cause the boom to fall which could result in injury or death.
Description of the Cause : The torque tool used to torque the turntable to rotation bearing bolts may not have achieved the specified torque value. Identification of Any Warning
that can Occur : Daily visual pre-shift inspection may indicate loose bolts. There may be loud popping sounds and excessive movement of the turntable if the turntable to rotation bearing bolts loosen.
Involved Components : Part 573 Safety Recall Report 24V-042 Page 2 Component Name 1 : Mounting Bolt
Component Description : Mounting bolt for turntable to rotation bearing, XT Pro & Optima Component Part Number : 480859 Component Name 2 : Mounting Bolt
Component Description : Mounting bolt for turntable to rotation bearing, Optima Component Part Number : 616702 Supplier Identification : Component Manufacturer
Name : Terex South Dakota, Inc Address : 3140 15th Ave SE
Watertown South Dakota 57201
Country : United States Chronology :
On July 17, 2023, the torque tool used to torque the XT Pro turntable to bearing bolts was found to be out of tolerance. The prior calibration check of that tool was on April 28, 2023. All machines in process were checked and corrected to have the correct torque. An engineering analysis was completed on October 4, 2023 and determined that the lower torque was inadequate. On October 5, 2023, the torque tool used to torque the Optima-TC55, Optima-HRX50, and Optima-HRX55 turntable to bearing bolts was found to be out of tolerance. The prior calibration check of that tool was August 25, 2023. Development of the field fix for the affected models began at that time. The potential unit list was developed by October 9, 2023. Although there are no reports of issues, the decision to recall was made on January 23, 2024. Description of Remedy :
Description of Remedy Program : The turntable to rotation bearing bolts are to be torqued to the specified
value at no cost to the owner. Terex will reimburse $150 per machine to have the turntable to rotation bearing bolts torqued. How Remedy Component Differs from Recalled Component : Recalled machines will not be visibly distinguishable from remedied machines. The information contained in this report was submitted pursuant to 49 CFR §573 Part 573 Safety Recall Report 24V-042
Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Identify How/When Recall Condition was Corrected in Production :
On July 17, 2023, the torque tool calibration interval was changed from every 3 months to monthly. Starting October 9, 2023, the first machine at the start of each shift will have its rotation bearing bolt torque checked with a second torque tool to verify that it meets the minimum required torque. Also on October 9, 2023, the torque tools in question had their calibration interval reduced from every month to every two weeks. Recall Schedule :
Description of Recall Schedule : Dealer notification will begin by February 9, 2024. Owner notification
will begin by February 23, 2024.
Planned Dealer Notification Date : FEB 09, 2024 – NR Planned Owner Notification Date : FEB 23, 2024 – NR
* NR – Not Reported

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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
SN724
DATE:
1/22/2024
REVISED:
TO:
Owners, Users, Dealers, and Installers
MODELS AFFECTED:
Optima-TC55, Optima-HRX50, Optima-HRX55, and XT Pro Aerial Devices
SUBJECT:
Rotation Bearing Bolts
Issue:
Terex single basket Optima-TC55, Optima-HRX50, and Optima-HRX55 model aerial devices, produced from August 28, 2023 through October 5, 2023, and Terex XT Pro model aerial devices, produced from May 2, 2023 through July 11, 2023 may have turntable to rotation bearing bolts that were not torqued properly. The improperly torqued bolts may loosen causing the bearing bolts to fail. Failure of the rotation bearing bolts could cause the boom to fall, 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 of the contents of this bulletin.
2. If the 6-month bolt torque inspection, as required in the Maintenance Manual, has been performed, it satisfies the requirements of this bulletin. Fill out the included Completion Form and return as specified on the form.
3. Perform a torque check on the turntable to rotation bearing bolts following the procedure in the Maintenance Manual and PA1016 (included). The torque for each unit is in the Quick Reference section of the Maintenance Manual and shown below:
a. Optima – 180 ft-lbs
b. XT Pro – 180 ft-lbs
4. If bolts are broken or fail to reach the specified torque, do not use the machine until these bolts are replaced. Only the broken bolts or bolts that do not reach the specified torque need to be replaced. Contact Terex Utilities or your dealer to order replacement bolts and washers. Retain broken bolts for 30 days from the time the Completion Form is submitted. After 30 days, the bolts can be discarded.
5. Fill out the Completion Form and return to Terex Utilities as directed on the form.
Continued Use:
After the bolt torque inspection, normal operations can be resumed following the guidance given in the unit Operator’s and Maintenance Manuals. Owners may continue to use the aerial device provided that all bolts maintain the specified torque value. The required 6-month bolt torque inspection must be performed on all rotation bearing bolts as specified in the Maintenance Manual. Always follow inspection and maintenance requirements as specified in the manuals.
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What Terex will Do:
Terex will reimburse $150 per machine to have the turntable to rotation bearing bolts torqued to 180 ft-lbs. There is to be no cost to the customer.
Locate your nearest Terex Utilities Service Center by visiting our website at www.terexutilities.com and select the Service tab. To schedule repairs with Terex Utilities Field Service, call 1-844-837-3948. The Terex Utilities Warranty Department can also be reached at 1-844-837-3948 or by email at [email protected]. Repairs can also be coordinated through our Dealer Service network as noted on the map included with this mailing.
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, the customer may contact you to arrange the repairs. Labor allowance is $150 per machine to torque the turntable to rotation bearing bolts. The pedestal to rotation bearing bolts are not included but must have the bolt torque inspected per the schedule in the Maintenance Manual.
Only single basket Optima-TC55, Optima-HRX50, Optima-HRX55, and XT Pro models from the timeframe listed in this bulletin are involved. If the owner contacts you call Terex Utilities Warranty Department at 1-844-837-3948 for instructions.
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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