SN684 – Rod Eyes May Fail – 2009-2016 Terex TCX60/85 & SML65/90 Aerial Devices

March 20, 2020 NHTSA CAMPAIGN NUMBER: 20V168000

Rod Eyes May Fail

If the rod eye fails the lift boom will drift down. The remaining cylinder may not support the boom fully and will slowly leak down. These scenarios increase the risk of an injury.

 

NHTSA Campaign Number: 20V168

Manufacturer Terex South Dakota, Inc.

Components EQUIPMENT

Potential Number of Units Affected 6

 

Summary

Terex South Dakota, Inc. (Terex) is recalling certain 2009-2016 TCX60/85 and SML65/90 aerial devices. The rod eyes on the 25ft lift cylinders may fail prematurely.

 

Remedy

Terex will notify owners, and dealers will replace the rod eyes and shims, free of charge. The recall began April 9, 2020. Owners may contact Terex customer service at 1-605-882-4000. Terex’s number for this recall is SN684.

 

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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TEREX

April 9, 2020

 

‘owner’
‘address1’
‘city’, ‘state’ ‘zip’

 

IMPORTANT SAFETY RECALL 20V-168

This notice applies to your vehicle

 

Dear Terex Equipment Owner,

 

REASON FOR NOTICE

SN684 is for the 25 foot double lift, part numbers 497981 & 498199, which have shims which do not fully support the elevator cylinder rod eyes. The threaded portion of the rod eye may fatigue and fail causing the lift to drift down. If one rod eye fails the lift is only supported by one of the two cylinders. The aerial boom may drift down contacting lower levels causing injury.

 

WHAT TEREX WILL DO

Terex will provide replacement rod eyes and shims for all 4 cylinders at no cost to the owner. Field Service kit Zl 582, which will repair all four cylinders, will be provided to the nearest Terex Utilities dealer or Field Service Technician for installation on your unit. Repair will take 8 hours.

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.

 

WHAT THE OWNER MUST DO

Immediately inspect the rod ends of the two cylinders on the lower lift boom and the two cylinders on the upper lift boom following the instruction in the Bulletin.

Inspection procedure:

1. From the lower controls raise the upper lift boom to 45 degrees and look under the cover at the shims at the rod end. If the shims are loose do not continue to use the unit until repaired.
2. From the lower controls raise the lower lift boom to 45 degrees and look under the cylinder cover at the shims at the rod end. If the shims are loose do not continue to use the unit until repaired.

3. If the shims on all four cylinders are still tight follow the continued use statement below.
4. If any of the shims are loose it indicates the rod eye is not torqued properly. The rod eye and shims must be replaced before further use.

Immediately inspect the rod ends before further use or contact 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

 

CONTINUED USE

Inform the users of the content of this bulletin and remind them of the daily pre-shift inspection requirements.

1. Inspect the cylinder rod ends daily before use as described above.
   1. If the shims are tight operate the lift with smooth feathering control. Use the lift with the arms positions above 45 degrees to reduce the load on the cylinder rod eyes before moving over lower structures or lines until repaired.
   2. If the shims are loose do not use the lift. Leave the lift tied down in the stored position. The aerial device can be used but the 25 ft lift must remain in stored position so the cylinders are not loaded.
2. Within 10 days of receipt of this bulletin contact 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.
3. Always follow inspection and maintenance requirements as specified in the manuals.

If you have any questions you can find your nearest dealer at this web site; https://www.terex.com/utilities/en/products/dealer-locator/index.htm.

If you take your unit to your dealer on the agreed service date and they do not remedy this condition on that date or within three (3) working days of scheduled appointment, we recommend you contact Terex Utilities Warranty department by calling 1-800-9828975.

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 https://www.safercar.gov.)

If you have had your unit repaired for this issue prior to receipt of this notice, you may be eligible for reimbursement. For more information, please contact Terex Utilities at the above contact information.

 

If you have sold or retired the unit please let us know by contacting the Terex Utilities Warranty department at 1-844-837-3948 or send the serial number and new owner contact information to [email protected] . Forward this Notice to the new owner within 10 days of receipt of this letter.

If you have leased this vehicle to another person, forward a copy of this notice to the lessee within ten days of your receipt of this notice.

Thank you for your immediate attention on this important matter,

Jeff Hegstrom
Product Support Manager

Our records indicate the following machines, registered to you, are involved in SN684.

Model	Serial Number
‘model’	‘Serial number’

 

Terex Utilities
SAFETY NOTICE	SN684
DATE: 3/13/2020	REVISED:

 

TO: Owners, Users, Dealers, and Installers

MODELS AFFECTED: TCX60/85, XML65/90

SUBJECT: 25 Double Lift 497981 & 498199

 

Issue:

The 25 foot double lift, part numbers 497981 & 498199, have shims which do not fully support the elevator cylinder rod eyes. The threaded portion of the rod eye may fatigue and fail causing the lift to drift down. If one rod eye fails the lift is only supported by one of the two cylinders. The aerial boom may drift down contacting lower levels causing injury.

 

Action:

Immediately inspect the rod ends of the two cylinders on the lower lift boom and the two cylinders on the upper lift boom.

Inspection procedure:

1. From the lower controls raise the upper lift boom to 45 degrees and look under the cover at the shims at the rod end. If the shims are loose do not continue to use the unit until repaired.
2. From the lower controls raise the lower lift boom to 45 degrees and look under the cylinder cover at the shims at the rod end. If the shims are loose do not continue to use the unit until repaired.
3. If the shims on all four cylinders are still tight follow the continued use statement below.
4. If any of the shims are loose it indicates the rod eye is not torqued properly. The rod eye and shims must be replaced before further use.

 

What the Owner Must Do:

Immediately inspect the rod ends before further use or contact 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

 

Continued Use:

Inform the users of the content of this bulletin and remind them of the daily pre-shift inspection requirements.

1 . Inspect the cylinder rod ends daily before use as described above.

1. If the shims are tight operate the lift with smooth feathering control. Use the lift with the arms positions above 45 degrees to reduce the load on the cylinder rod eyes before moving over lower structures or lines until repaired.
2. If the shims are loose do not use the lift. Leave the lift tied down in the stored position. The aerial device can be used but the 25 ft lift must remain in stored position so the cylinders are not loaded.
3. Within 10 days of receipt of this bulletin contact 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 provide replacement rod eyes and shims for all 4 cylinders at no cost to the owner. Field Service kit Zl 582, which will repair all four cylinders, will be provided to the nearest Terex Utilities dealer or Field Service Technician for installation on your unit.

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. Labor allowance is $960.

Only TCX60/85 and XML65/90 models with 25 ft lifts 497981 & 498199 are involved utilizing cylinders 498034 and 498035. If the owner contacts you call TEREX Utilities Warranty Department at 1-844-8373948 for instructions and to arrange shipment of parts.

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

Terex and local industry standards (CSA and ANSI) requires that 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].

 

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16 Affected Products

Vehicles

MAKE	MODEL	YEAR
TEREX	SML	2009-2016
TEREX	TCX	2009-2016

 

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6 Associated Documents

ISSUED Owner Notification Letter(Part 577)

RCONL-20V168-7851.pdf 754.165KB

 

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Recall Quarterly Report #1, 2020-2

RCLQRT-20V168-9043.PDF 211.123KB

 

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Defect Notice 573 Report

RCLRPT-20V168-8147.PDF 212.832KB

 

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Recall Acknowledgement

RCAK-20V168-3726.pdf 245.391KB

 

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Manufacturer Notices(to Dealers,etc)

RCMN-20V168-3006.pdf 247.698KB

 

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Recall Quarterly Report #2, 2020-3

RCLQRT-20V168-7804.PDF 211.216KB

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=20V168&docType=RCL

 

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Last update on 2026-05-27 / Affiliate links / Images from Amazon Product Advertising API

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