Terex Utilities

PRODUCT NOTICE
DATE:

4/14/2021

PN690
REVISED:

TO: Owners, Users, Dealers, and Installers
MODELS AFFECTED:
SUBJECT:

TL80, TL80/112, TL100

Transmission TL Updates

Issue:
Terex Transmission TL models TL80, TL80/112, and TL100 aerial devices, produced from March 2019
through August 2020, should be upgraded to current production status. There have been several running
changes and improvements including: boom tie down, jib transport position, and potential for leaking
control valves. Failure to correct the indicated issues may result in leaking hydraulic fluid at the
control valves and damaged components during road travel.

Action:
What the Owner Must Do:
1. Inform all users, operators, and supervisors that the following areas must be inspected within 30
days of receipt of this bulletin.
2. Inspect the unit to determine if your unit has the following conditions using the figures as
reference:
Boom Stowing
The following upgrades ease stowing of the machine and improve road travel.
a. Ratchet style versus cam over style upper boom hold down (TL80/112 only) – Field
Service Kit Z1571
The ratchet strap is now recommended for securing the upper boom.

Figure 1. Cam style strap, this
update applies

Terex South Dakota, Inc.
3140 15th Ave SE
Watertown, SD 57201 USA
1-844-837-3948 • Fax 1-605-882-1842

Figure 2. Ratchet style strap, this
update may not apply

b. Added elevator pedestal side support (TL80/112 only) – Field Service Kit Z1571
The elevator side supports aid guiding the boom into the latch when stowing the machine
when the truck is not level.

Figure 3. Elevator pedestal side support
not installed, this update applies

Figure 4. Elevator pedestal side support
installed, this update may not apply

c.

Lower boom rest wear pads with chamfered edge (TL80/112 only) – Field Service Kit
Z1586
Unchamfered wear pads can be damaged when lower boom is stored if the lower boom
is not aligned with the rest. The chamfered pads help guide the lower boom into position.

Unchamfered
wear pad

Figure 5. If the upper wear pads for the lower boom rest
are unchamfered, this update applies. If the upper wear
pads are chamfered, this update may not apply.

2

Chamfered
wear pad

d. Bolts for compensation link changed from hex head to button head (TL80 & TL100 only)
– Field Service Kit Z1596
If the location of the lower boom rest falls in the highlighted area, the bolts should be
changed to button head bolts as the hex head bolts can damage the wear pad. This only
applies to the TL80 and TL100; it does not apply to the TL80/112 units with a hydraulic
lift.

Figure 6. If the compensator link lower
bolts are hex head, this update applies

Figure 7. If the compensator link lower
bolts are button head, this update may
not apply

e. Basket rest reinforcement – Field Service Kit Z1571 (TL80/112) or Field Service Kit
Z1573 (TL80 & TL100)
A reinforcement is added to the basket rest support to stiffen the support tube.

Figure 8. Basket rest reinforcement
installed, this update may not apply

3

Hydraulic Leaks and Backpressure Reduction
a. Hydraulic leaks from the upper and lower control valves
b. Additional return line and atmospheric vent at upper control valve (TL80, TL80/112,
TL100) – Field Service Kit Z1583
In order to reduce backpressure and potential related hydraulic leaks, an additional return
line and atmospheric vent is added to the upper control valve.

Added return
hose

Figure 10. Upper control valve
extra return line and vent added,
this update may not apply

Figure 9. Upper control valve
extra return line and vent not
added, this update applies

c.

Atmospheric
vent

Additional return line at the lower control valve (TL80, TL80/112, TL100) – Field Service
Kit Z1583
In order to reduce backpressure and potential related hydraulic leaks, an additional return
line is added to the lower control valve.

Figure 11. TL80/112 Control Valve. If
the hose shown is present, this
update may not apply

4

Figure 12. TL80 & TL100 Control
Valve. If the hose shown is present,
this update may not apply

d. Replacement lower/upper selector section seals (TL80, TL80/112, TL100) – Field Service
Kit Z1610
A design improvement was made to replace the o-ring seals with quad ring seals to
reduce leaks from the control valves.

Figure 13. Location of lower/upper selector control valve section.
If the seals haven’t been replaced this update may apply.

Jib Storage for Travel
a. Jib storage change makes it easier to access the controls– Field Service Kit Z1571
(TL80/112) or Field Service Kit Z1573 (TL80 & TL100)
The rearmost jib storage position is plugged as it does not allow easy control access in
that position. An additional jib storage position is added to allow the jib to store more inline with the upper boom, allowing for easier control access and platform entry.

Figure 14. Jib can store over
rear corner of platform, this
update applies

Jib storage hole plugged

Jib storage hole added

Figure 15. Jib storage limited to
eliminate over rear position, this
update may not apply

5

Extension Cylinder Support
a. Addition of metal support bracket for the end of the extension cylinder (TL80, TL80/112,
TL100) – Field Service Kit Z1606
A metal support is added to aid in properly supporting the cylinder.

Metal support bracket
along with plastic support
Figure 16. If the metal support shown is
present, this update may not apply

3. If your unit has items that do not match all of the correct figures above, this bulletin applies.
Follow the continued use section below.
4. If your unit has all of the items completed listed above, this bulletin does not apply. Always follow
operation, inspection, and maintenance requirements as specified in the manuals.

Continued Use:
All machine users and operators must be notified of the following requirements for continued use of
affected machines:
1. The affected machines may remain in service, until the next scheduled service interval, provided
there are no hydraulic leaks.
2. Within 30 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.
3. Always follow inspection and maintenance requirements as specified in the manuals.

What Terex will Do:
Terex will provide Field Service Kits Z1571, Z1573, Z1583, Z1586, Z1596, Z1606, and Z1610, parts and
labor, for units built prior to September 2020, at no cost to the customer through December 31, 2021.
The kits make the following improvements:

•
•
•
•
•
•
•

Z1571 – Ratchet strap upper boom tie down, elevator side support, basket rest, jib storage
limitation
Z1573 – Basket rest, jib storage limitation
Z1583 – Additional return plumbing for control valves to reduce backpressure
Z1586 – Chamfered wear pads for lower boom rest
Z1596 – Button head bolts for compensation link
Z1606 – Additional extension cylinder support
Z1610 – Lower/upper control selector seals

6

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 30 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: Only Terex TL80, TL80/112, and TL100 models are involved. 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.
If the owner contacts you call Terex Utilities Warranty Department at 1-844-837-3948 for instructions and
to arrange shipment of parts.
Affected units, as shown on the owner letter, will have the repairs performed at no charge to the owner
until December 31, 2021.
Important: Some of the involved units may be in rental fleets. Terex 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.
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].

7