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Terex TB44 Manlift intermittent control problem

Discussion in 'Other Construction/Demolition Equipment' started by texascadillac42, Mar 15, 2011.

  1. texascadillac42

    texascadillac42 Well-Known Member

    Joined:
    Apr 2, 2008
    Messages:
    82
    Location:
    Midwest
    Machine is a Terex TB44 man lift. The problem I am having with this machine is that the controls in the basket will intermittently stop responding/not work at all. When the controls do fail, the functions on the ground control panel all work fine.

    When the controls are dead in the control panel, everything is dead. The red emergency shut off switch will not shut the machine down, none of the joystick controls or toggle switches do anything.... etc. Sometimes simply pushing down on the foot pedal will make the engine stall.

    The master on/off/crank switch on the basket control panel does seem to have a hard spot in it, and I am wondering if the master switch has some internal problem causing it to stop providing power to the controls....

    When the machine is operating correctly, everything thing works well, very smooth, crisp...etc but when it starts acting up it seems that no amount of fiddling with it helps.

    I may replace this just to rule out a potential problem.

    Does anyone have any thoughts or ideas?
     
  2. bobb

    bobb Well-Known Member

    Joined:
    Mar 3, 2011
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    136
    Occupation:
    Mechanic
    Location:
    onarock
    by master do you mean the red e-stop? or the start-e power switch? you may try looking at your power cable where it twists and turns at the basket. it may have gotten damaged. you may also need to check the connectors at the botttom of the ground control box. remove the hex head bolt and pull the plug down. check for pushed in pins or sockets or green corrosion. clean it up good and slap some silicon grease on there.
     
  3. texascadillac42

    texascadillac42 Well-Known Member

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    Location:
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    By master I mean the rotary switch that can crank the motor over.
     
  4. willie59

    willie59 Super Moderator

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    Occupation:
    Service Manager
    Location:
    Knoxville TN
    Worst thing about the Terex machines is they use the OEM Optimizer digital control system. They are a complex controller that you can't do anything with unless you have the Optimizer scan tool, and one model of scan tool is like 800 dollars. The Optimizer controls every function of the machine, starting, stopping, and operation. Aside from that, that start/stop switch at the platform is pretty common, should be able to find a replacement at a good auto parts store, Borg Warner or Standard Ignition catalog. As mentioned by bobb, be sure and look closely at the cable that runs from platform to ground. Look for any bad spots in the cable.
     
  5. bobb

    bobb Well-Known Member

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    that rotory switch he mentioned is a big red goofy lookin switch. i have never seen one like it exept on a terex. not to say that i am a worldly person in the equipment world. i have just never seen it anywheres else. i also forgot to mention lookin at the connector at the platform control box. these things are compputer controlled so a little bit of water in them can be a big problem. thats why i like to slather on some silicon grease. it may not be the factory advise but i have found it useful. lookin at the itty bitty leds on the puter boards is sometimes useful too. put on your reading glasses cause your gonna need um.
     
  6. texascadillac42

    texascadillac42 Well-Known Member

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    Sounds good, thanks guys. When it dries up a little around here I will start to use the machine again, and pay attention to the LEDs, as well as get a new master switch for it.
     
  7. bobb

    bobb Well-Known Member

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    Occupation:
    Mechanic
    Location:
    onarock
    its been a long time but if your engine compartment has the metal plate with the dorf solenoid on it along with the start cube type relay and whatnot. you may want to keep it covered wit some sort of plastic bag, cause the rain tends to get to it.......if i remember it right. also if yours is deutz powered remember that the cam is belt driven.
     
  8. bcamp

    bcamp New Member

    Joined:
    Apr 6, 2012
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    1
    Location:
    TENNESSEE
    i have a TB42 Terex that the aerial controls won't rotate l/right,boom ext./retract,drive fwd.rev,boom lift/lower and they work on the ground control station.Checked all wires for shorts and found none and getting a good 13.5 volts to all controls. What did you end up finding wrong with yours? Any ideas what i should check next?
     
  9. myrahush

    myrahush Member

    Joined:
    Apr 17, 2012
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    6
    Location:
    UK
    Terex is really appreciate the smooth performance.
     
  10. wookiee

    wookiee Member

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    Jan 4, 2015
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    Occupation:
    Retired HV Lineman/Troubleshooter
    Location:
    Springfield, SD
    Any idea where I can buy/rent/borrow one?


    Genie doesn't respond to requests.
     
  11. Hardline

    Hardline Senior Member

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    Occupation:
    Small business owner
    Location:
    Waxahachie Texas
    You will have to go through the dealer network. Good luck on any help as most places that are rental companies can not find the time to fix their own machines never mind help you with yours. Guys like us are left out here swinging in the breeze.
     
  12. Andy 9000

    Andy 9000 New Member

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    Sep 25, 2017
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    Location:
    Rimbey, Alberta, Canada
    Were you able to solve your problem? I'm having a similar problem with a Terex TB44, only I've inherited it after someone else has had a good go at trying to fix it first. I am trying to repair this machine in my spare time which means when it's dark out or raining. I thought I could break it down to go through it and verify all connections first so I removed the basket controls so that I could go through it on the bench. I found a schematic online through the Genie site, but seems to be a generic one that they have on there for every model of Terex TB lifts and is definitely different than this one. I've talked to our local Genie service tech who called all the contacts that he knew at Terex or that had worked on them and no one seems to have any schematics beyond what I've already found. I'm wondering if anyone may have another resource where I may be able to find the proper schematic? It's a 1998 Terex TB44 ser: 99610030, Ford 4cyl gas engine, OEM SuperFlex system. Any help would be greatly appreciated!
     
  13. Garyo

    Garyo New Member

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    Mayer Az
    Andy, were you able to solve your problem?
     
  14. gbearce

    gbearce New Member

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    Feb 6, 2019
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    Location:
    Astoria Illinois
    I have same problem. Terex Mod Tb 42. Any ideas for help?
    Does anyone work on them? Illinois
     
  15. TVA

    TVA Senior Member

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    Location:
    USA
    Here I sit and whine that I have to work on Grove Manlift!
    And there’s people who have it real bad - they have to mess with Terex!
     
  16. Andy 9000

    Andy 9000 New Member

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    Sep 25, 2017
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    2
    Location:
    Rimbey, Alberta, Canada
    Yes I've been able to get mine working, I still have a couple of things to repair but it is now functional which is great. I eventually got a hold of someone helpful at Terex, and although they were not able to help me they told me the name of a company that prints all of their manuals and I was able to get a complete manual for this machine from them (at a cost of $250 USD). The manual was a great help for the most part, I think it was definitely money well spent - this allowed me to correct and understand a lot of the wiring on this particular machine. However I also discovered that I had a problem with one of the main circuit boards (I don't remember the numbers off the top of my head), and of course these are no longer made and the cheapest 'new' one I could find was $2500. I ended up sending my original one to Providence Industrial and they repaired it, still cost me $700. Once I had the control wiring sorted and the board fixed I was in business (of course I had a bit of engine tune-up and carb adjustments, hoses to replace, etc.), but the electrical was the real stumbling block for me. If there's something in particular you need information on I can send you some sheets from the manual (or I can look up the name of the company if you wanted to order your own), for the most part it's the same as the online manual you can find on the Genie site, there's just a few more schematics and of course it's much clearer and easy to read. It's definitely a more complex control system then I'd worked on in the past, so it's pretty tough to help you trouble shoot without more information. The OEM control system with the Optimizer had me worried, I'd actually been talking to an engineer at OEM that was trying to help me, although there was some information that was proprietary and he couldn't share, but fortunately when I got the board back everything seems to be just fine so I guess I side stepped that issue. I also had a weird setup in mine - it seemed to have the control system from a TB60 in my TB44 (with some of the functions transmitted wirelessly from the basket), but with the manual I was able to make sense of it. I think mechanically it's a great machine, just some weak and expensive control system components.