BT3870 Operators 12261-533

Table of Contents
Introduction ...................................................................................................... 5
Chassis Configurations ............................................................................. 5
Nomenclature............................................................................................ 6
Standards.................................................................................................. 8
Intended Use............................................................................................. 9
Bulletin Distribution and Compliance...................................................... 10
Contacting Manufacturer ........................................................................ 11
Transfer of Machine Ownership .............................................................. 12
Safety ............................................................................................................. 13
Safety Introduction.................................................................................. 13
Alert System............................................................................................ 14
General Safety......................................................................................... 18
Safety Guidelines ............................................................................. 18
Safety Sign Maintenance ................................................................. 19
BT28106 Safety Sign Locations ...................................................... 20
Personal Protection Equipment .............................................................. 33
Workplace Safety .................................................................................... 34
Effects of Wind Conditions ..................................................................... 42
Lightning Storm....................................................................................... 44
Lock Out & Tag Out ................................................................................ 45
Access/Egress ........................................................................................ 47
Personal Safety ....................................................................................... 51
Seat Belts................................................................................................ 53
Assembly........................................................................................................ 55
Wire Rope Reeving ................................................................................. 55
Dead Ending Wire Rope in Socket.......................................................... 58
Boom Installation ................................................................................... 59
BT3870 Jib Installation............................................................................ 60
BT28106 Jib Installation.......................................................................... 77
Changing Jib Offset ................................................................................ 86
Description Of Machine and Controls ............................................................ 89
Outrigger Controls................................................................................... 89
Power Take-Off ....................................................................................... 91
Controls................................................................................................... 95
Front Stabilizer ...................................................................................... 103
Winch Inching Valve Switch .................................................................. 104
Rated Capacity Indicator and Anti-Two Block...................................... 105
Rated Capacity Indicator System .................................................. 105
P/N 12261-533 REVISED: October 2011 i
Contents
Anti-Two Block Components......................................................... 106

Inspection..................................................................................................... 109
Suggested Hydraulic Crane Inspection Checklist ................................ 109
Wire Rope Inspection............................................................................ 112
Operating Instructions.................................................................................. 115
Job-Site................................................................................................. 115
Job Site Setup Procedure.............................................................. 115
Outrigger Positioning ..................................................................... 116
Work Site Position ......................................................................... 117
Cold Weather Operation ................................................................ 118
General Operational Issues ................................................................... 119
General Rules................................................................................. 119
Safety Devices ............................................................................... 121
Training and Operator Qualifications ............................................. 122
Operator Aids................................................................................. 123
Load Handling Operations ............................................................. 124
Max. Load and Boom Angle Charts...................................................... 125
Using the Maximum Load Chart .................................................... 125
Operating Radius ........................................................................... 128
Boom Angle Placards .................................................................... 129
Operating the Unit................................................................................. 130
Operating the Unit.......................................................................... 130
Initiating Operation......................................................................... 131
Arm and Hand Signals ................................................................... 132
Lifting the Load .............................................................................. 134
Emergency Procedures......................................................................... 136
Emergency Procedures ................................................................. 136
Emergency Boom Retraction......................................................... 137
Emergency Lowering of Boom ..................................................... 138
Emergency Rotation ...................................................................... 139
Emergency Retraction of Outriggers ............................................. 140
Roading the Unit ................................................................................... 141
Disassembly ................................................................................................. 143
BT3870 Jib Stowage............................................................................. 143
BT28106 Jib Stowage........................................................................... 156
Maintenance................................................................................................. 165
Safety Practices .................................................................................... 165
General Work Practices ........................................................................ 167
ii P/N 12261-533 REVISED: October 2011
Storing Components ............................................................................. 168
Cleanliness ............................................................................................ 169
Master Lube Chart ................................................................................ 170
Maintenance Checks and Lubrication .................................................. 171
90-Day Maintenance Items ................................................................... 174
Semi-Annual Maintenance Items .......................................................... 175
Filters and Maintenance........................................................................ 176
Rotation System Maintenance and Troubleshooting............................ 179
Swing System ................................................................................ 179
Care and Maintenance of the Rotation System............................. 181
Rotation Gearbox and Gear Teeth................................................. 186
Winch Lubrication ................................................................................. 187
Wire Rope Lubrication .......................................................................... 188
Storage.................................................................................................. 189
Storage .......................................................................................... 189
Engine Storage .............................................................................. 191
Transmission storage..................................................................... 194
Chrome Cylinder Rod Storage....................................................... 195
Restoration to Service ................................................................... 197
Restoring Engine to Service........................................................... 198
Restoring Transmission to Service ................................................ 199
Specifications............................................................................................... 201
Pumps and Function Speeds................................................................ 201
Troubleshooting ........................................................................................... 203
Winch System Maintenance and Troubleshooting ............................... 203
Winch Maintenance and Repair..................................................... 203
Two-Speed Winch Function .......................................................... 205
Service / Parts .............................................................................................. 209
General Work Practices ........................................................................ 167
Hydraulic System Description............................................................... 210
Repairs-Adjustments-Remarks Log...................................................... 212
Control Valves and Pressures ............................................................... 214
Outrigger and Cylinder Maintenance and Troubleshooting .................. 219
Outrigger Position Sensors ............................................................ 219
Hoist Cylinder ................................................................................ 221
Outrigger Cylinder.......................................................................... 225
Extension Cylinder ......................................................................... 230
Boom Maintenance, Adjustment and Repair ........................................ 237
P/N 12261-533 REVISED: October 2011 iii
Contents
BT3870 Wear Pad Adjustment and Replacement ......................... 237

BT28106 Wear Pad Adjustment and Replacement ....................... 252
Boom Assembly............................................................................. 259
BT3870 Boom Cable Adjustment Procedure ................................ 279
BT28106 Boom Cable Adjustment Procedure .............................. 281
Rotation Gear and Gearbox .................................................................. 284
Removal/Installation of Rotation Gear and Gearbox ..................... 284
Inspection of Rotation Bearing Clearance ..................................... 286
Backlash Adjustment ..................................................................... 288
Appendix ...................................................................................................... 291
Conversion Tables ................................................................................ 291
Average Weight of Materials ................................................................. 295
Torque Specs -SAE & Metric ................................................................ 298
Man Basket Installation & Operation Manual........................................ 300
Greer Insite Operation's Manual ........................................................... 301
BT510 Operator's Manual..................................................................... 302
iv P/N 12261-533 REVISED: October 2011

Introduction
Chassis Configurations
THE BT3870 BOOM TRUCK FROM TEREX COMES
IN TWO CONFIGURATIONS, THE
BT3870T FOR INSTALLATION ON A
TANDEM REAR AXLE CHASSIS AND
THE BT3870S FOR INSTALLATION
ON A SINGLE REAR AXLE CHASSIS.
• THE BT3870S MODEL CAN BE INSTALLED ON EITHER TANDEM OR SINGLE AXLE

CHASSIS, WHILE THE BT3870T CAN ONLY BE INSTALLED ON A CHASSIS WITH
TANDEM REAR AXLES.
• AT NO TIME CAN A BT3870T BE INSTALLED ON A SINGLE REAR AXLE CHASSIS
WITHOUT PRIOR APPROVAL FROM TEREX CRANES.
• IF THE MACHINE YOU ARE OPERATING IS LABELED AS A BT3870T AND IS
MOUNTED ON A SINGLE AXLE CHASSIS, STOP OPERATION IMMEDIATELY AND
USING LOCK OUT / TAG OUT PROCEDURES, IMMOBILIZE THE MACHINE.
CONTACT YOUR TEREX SERVICE REPRESENTATIVE IMMEDIATELY TO DISCUSS A
RESOLUTION.
THE BT28106 BOOM TRUCK FROM TEREX COMES

ONLY WITH ONE CONFIGURATION
USING A TANDEM REAR AXLE
CHASSIS.
• AT NO TIME CAN A BT28106 BE INSTALLED ON A SINGLE REAR AXLE CHASSIS.
P/N 12261-533 REVISED: October 2011 5

Introduction
Nomenclature
This manual contains instructions and information on the operation, maintenance,
lubrication and adjustments of the Boom Truck. The operator should not attempt to operate
the machine before he has gained a thorough understanding of the material presented in
the following pages. To aid in understanding the contents of this manual, the following
terms will always have the meanings given whenever they are used.
1. TURRET The turret weldment and swing mechanism.
2. BOOM The telescopic boom with hydraulic winch, lift cylinder,
hook block assembly, and jib arrangement.
3.PEDESTAL The structure that supports the turret weldment,
outriggers, and operator platforms on the truck.
4. FLATBED The deck of the boom truck.
5. SUBFRAME The frame of the crane that is mounted to the truck
chassis and supports the flatbed and pedestal.
6. OUTRIGGERS The beams, cylinders, floats, boxes, hydraulic control
system.
7. TRUCK The vehicle that all boom and operator structures are
mounted on.
RIGHT HAND/LEFT All references to right or left hand will correspond to the
HAND operator’s right or left hand when he is facing forward
from the operator’s platform, with the truck cab to his
back.
BT3870
6 P/N 12261-533 REVISED: October 2011

BT28106

Introduction
Standards
Many aspects of crane operation and testing are discussed in standards published by the
American National Standards Institute. These Standards are updated on an annual basis
with addendum, which are sent by American Society for Mechanical Engineers (ASME) to
the original purchasers of the standard. Terex® recommends that you purchase and refer
to the following standards:
ANSI/ASME B30.5 – Mobile & Locomotive Crane (Latest Version)
These standards may be purchased by:

Mail: American Society of Mechanical Engineers
Customer Service Department
22 Law Drive
Fairfield, New Jersey 07004
Phone: 800.843.2763
Fax: 973.882.8113
Internet: www.asme.org
Copyright
This manual is intended for use by personnel responsible for operation, maintenance, repair
and supervision activities involving the machine described within.
This manual is copyrighted. It shall not, either in whole or in part, be reproduced,

transmitted, or used for the purpose of competition without our prior written consent.

Intended Use
This machine and its approved attachments are designed to lift, lower and move freely
suspended loads within the rated capacity of the crane. Use of this product in any other
way is prohibited and contrary to its intended use.

Introduction
Bulletin Distribution and Compliance

Safety of product users is of paramount importance to Terex. Various bulletins are used by
Terex to communicate important safety and product information to dealers and machine
owners.
The information contained in bulletins is tied to specific machines using the machine model
number and PIN/serial number.
Distribution of bulletins is based on the most current owner of record along with their
associated dealer, so it is important to register your machine and keep your contact
information up-to-date.
To ensure safety of personnel and the reliable continued operation of your machine, be
sure to comply with the action indicated in a respective bulletin.

Contacting Manufacturer
At times it may be necessary to contact the manufacturer of this machine. When you do, be
ready to supply the model and PIN/serial number of your machine, along with your name
and contact information. At minimum, the manufacturer should be contacted for:
• Accident Reporting
• Questions regarding product applications and safety
• Standards and regulations compliance information
• Questions regarding product modifications
• Current owner updates, such as changes in machine ownership or changes in your
contact information (see Transfer of Machine Ownership on page 12 for more
information).
Manufacturer contact information:
Terex Cranes
202 Raleigh St
Wilmington, NC 28412
1 (877) MY-TEREX
1 (877) 698-3739

Introduction
Transfer of Machine Ownership

If you are not the original owner of this machine, please provide the model number and PIN/
serial number of your machine, along with your name and the date of transfer of ownership.
This will ensure that you are the owner on record for this machine, allowing you to receive
any applicable notices and advisories in a timely manner.

Safety
Safety Introduction
Owners, Users, and Operators:
Terex Cranes appreciates your choice of our machine for your application. Our number one
priority is user safety, which is best achieved by our joint efforts. We feel that you make a
major contribution to safety if you as the equipment users and operators:
1. Comply with OSHA, Federal, State, and Local Regulations.
2. Read, Understand, and Follow the instructions in this and other manuals supplied with
this machine.
3. Use Good, Safe Work Practices in a common sense way.
4. Only have trained operators - directed by informed and knowledgeable supervision -
running the machine.
NOTE: OSHA prohibits the alteration or modification of this crane without written
manufacturer's approval. Use only factory approved parts to service or repair this unit.
If there is anything in this manual that is not clear or which you believe should be added,
please send your comments to Technical Publications Coordinator, Terex Cranes, 106 12th
Street SE, Waverly, Iowa 50677; or contact us by telephone at (319) 352-3920.
THIS SYMBOL MEANS YOUR SAFETY IS INVOLVED! READ, UNDERSTAND,

AND FOLLOW ALL DANGER, WARNING, AND CAUTION DECALS ON YOUR
MACHINE.
Many aspects of crane operation and testing are discussed in standards published by the
American National Standards Institute. These Standards are updated on an annual basis
with addendas, which are sent by ASME to the original purchasers of the standard. Terex
recommends that you purchase and refer to the following standards.
ANSI/ASME B30.5 - Mobile & Locomotive Crane (Latest Version)
These standards can be purchased from:
American Society of Mechanical Engineers

Information Central Orders/Inquiries
P.O. Box 2300
Fairfield, NJ 07007-2300
800-843-2763
Email: infocentral@asme.org

Safety
Alert System
SAFETY ALERT SYMBOL
The safety alert symbol is used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible injury or death
SAFETY ALERT SYMBOL
MACHINE DECAL HAZARD CLASSIFICATION SYMBOLS
A multi-tier hazard classification system is used on machine decals to communicate

potential personal injury hazards. The following signal words used with the safety alert
symbol indicate a specific level of severity of the potential hazard. Signal words used
without the safety alert symbol relate to property damage and protection only. All are used
as attention-getting devices on decals and labels fixed to the machinery to assist in
potential hazard recognition and prevention.
1. DANGER - Indicates an imminently hazardous situation which, if not avoided,

will result in death or serious injury.
2. WARNING - Indicates a potentially hazardous situation which, if not avoided,

could result in death or serious injury.
3. CAUTION - Indicates a potentially hazardous situation which, if not avoided,

may result in minor or moderate injury.
4. NOTICE - Notice used without a safety alert symbol indicates a hazardous

situation, which, if not avoided, could result in property damage.

SYMBOLS AND PICTORIALS
Hazard Avoidance
CRUSH HAZARD Stay Clear of Moving Turret
and Boom.
Crushing of fingers
or hand - force
applied two
directions (pinched).
CRUSH HAZARD Keep clear of moving machine.
Death or Serious
Injury can result
from contact with
moving machine.
Safety Alert Symbol Use personnel lift in

compliance with OSHA and
ANSI regulatory instructions.
Skin Injection From Use Cardboard or Wood to

High Pressure Fluid. Check for Leaks.
Falling From NO RIDERS

Wheeled Machine.
Hand Entanglement Keep Hands Clear of Winch

In Pulley / Winch. and Load Line.

Safety
Hazard Avoidance
Entanglement in Stay Clear of Rotating Shafts.
Drive Shaft.
ENTANGLEMENT Keep away from fan and belt

HAZARD when engineis running. Stop
Rotating parts can engine before servicing.
cause personal
injury.
Explosion / Burn Keep all open flames and

Hazard sparks away. Wear personal
Will cause death, protective equipment, including
burns or blindness face shield, gloves and long
due to ignition of sleeve shirt.
explosive gases or
contact with READ MANUALS
corrosive acid. Read all manuals prior to
operation.
DO NOT OPERATE equipment

if you do not understand the
information in the manuals.
BURN HAZARD No smoking. No flame. Stop

Fuel and fumes can engine.
explode and burn.
BURN HAZARD Allow surfaces to cool before

Contact with hot servicing.
surfaces can cause
burns.

Hazard Avoidance
Falling from height. Use personnel lift or
appropriate ladder to reach
high places.
Maintain 3-Point Contact when

using access system.
Two blocking the Check Anti-two Block System.

crane can cause
death, serious injury
or property damage.
Do not allow the
hook block to
contact the boom
tip by hoisting up,
extending or
lowering the boom.
CRUSH HAZARD Stay Clear of Outriggers.
Contact with
moving outriggers
can result in death
or serious injury.
Electrical Shock / Stay Sufficient Distance From

Electrocution from Electrical Power Lines.
Crane to Power
Line Contact.
These are general safety rules, which must be followed. You are also required to
read and understand the Operators Manual as there are instructions, which are
more detailed specific to this machine.

Safety
General Safety
Safety Guidelines
These are general safety rules, which must be followed. You are also required to
read and understand the Operators Manual as there are instructions, which are
more detailed specific to this machine.

Safety Sign Maintenance
Replace any missing or damaged safety signs. Keep operator safety in mind at all times.
Use mild soap and water to clean safety signs. Do not use solvent-based cleaners because
they will damage the safety sign material.

Safety
BT28106 Safety Sign Locations
BT28106 Boom Safety Sign Locations- Curbside

BT28106 Boom Safety Sign Locations- Streetside

Safety
BT28106 Mainframe Turret Safety Sign Locations

BT28106 Mainframe Console Safety Sign Locations- Top VIew

Safety
BT28106 Mainframe Turret - Curb Side & Console Front View Sign Locations

BT28106 Mainframe Console - Right Side Safety Sign Locations

Safety
BT28106 Flatbed - Curb Side Safety Sign Locations

BT28106 Flatbed/Hydraulic - Street Side Safety Sign Locations

Safety
BT28106 Hydraulic Tank and Outrigger Stow Safety Sign Locations

BT28106 Outrigger Extended Safety Sign Locations

Safety
BT28106 Rear Flatbed Safety Sign Locations

BT28106 Jib Safety Sign Locations

Safety
BT28106 Front Outrigger & Block Safety Sign Locations
BT28106 Inching Winch Safety Sign Locations

Personal Protection Equipment
Before beginning operation, service or maintenance conduct a hazard assessment to
determine appropriate personal protective equipment for the working conditions and the
operating environment. For more information refer to the applicable OSHA 1910.132
Standards, ANSI Standards, Federal, State, Local and Jobsite Regulations.
Common Types of PPE
Safety Glasses – Impact resistant lenses offering

limited protection for the user’s eyes from flying debris.
Ear Plugs – A device that is inserted into the ear canal

to protect the user’s hearing from loud noises or the
intrusiton of foreign bodies and dust.
Hard Hat – A helmet used to protect the user’s head

from injuries obtained from falling objects and debris.
Leather Gloves – Gloves used to protect the user’s

hands from minor cuts and other injuries.
Safety Boots – A boot designed to protect the user’s

feet from various types of injury such as cuts, puncture
wounds, crushed toes, etc.

Safety
Workplace Safety
HANDLING PERSONNEL
Cranes can only be used to lift people when it is the least hazardous way to do the job.
(See OSHA 1926.550g, and ASME / ANSI B30.23.)
TRAINING AND KNOWLEDGE
1. Safety must always be the operator's most important concern.

2. Do not operate this crane until you have been trained in its operation. This crane must
only be operated by trained personnel, who have demonstrated their ability to do so
safely.
3. Comply with the requirements of current Occupational Safety and Health
Administration (OSHA) standards, the current American National Standards Institute
(ANSI) B30.5 latest edition.
4. Read and understand all decals and warnings.
5. Read and understand the Rating Chart.
6. Know that the crane can safely lift each load before attempting to lift.
7. The operator must understand crane signals and take signals only from designated
signal people. However, the operator must obey the stop signal from anyone.
OPERATOR'S RESPONSIBILITIES
1. Read and understand the Operator's Manual.

2. Make sure the machine is in proper order and that all operational aids and warning
signals are functional before operating.
3. Keep the machine clean, including all instrumentation, windows, lights and other
glazed surfaces.
4. Remove all oil, grease, mud, ice and snow from walking surfaces.
5. Store all tools, rigging and other necessary items in the tool box.
6. Never lift a load without consulting the Rating Chart Manual located in the operator’s
cab.
7. Know the load to be lifted.
(Continued on next page ...)

OPERATOR'S RESPONSIBILITIES
8. Be alert, physically fit and free from the influences of alcohol, drugs or medications
that might affect the operator's eyesight, hearing, or reactions.
9. Keep people, equipment and material outside of the work area.
10. Signal person must be used when the operator's vision is blocked or when working in
hazardous areas such as near power lines or people.
11. Keep a fully charged fire extinguisher and first aid kit in the operator's cab at all times
and be familiar with the use of these items.
12. Always know the location of other machinery, vehicles, personnel and other obstacles
in the work area.
13. Never permit people on the machine platform while the machine is in operation.
14. Make sure everyone is clear of the work area before moving the hook, boom, load or
outriggers.
15. Start and stop movements smoothly and swing at speeds that will keep the load under
control.
16. Keep at least two full wraps of wire rope on drum when operating.
17. Use tag lines to keep loads under control when feasible.
18. Keep the load as close to the ground as possible.
19. Use shortest boom length required to complete job.
20. Never leave a running machine unattended or load suspended.
21. Always use outriggers in accordance with requirements of the Load Rating Chart and
Operator's Manuals.
SIGNAL PERSON'S RESPONSIBILITIES
1. Standard crane signals must be used, and understood.

2. Assist the operator in safe and efficient operation, without endangering people or
property.
3. Have a clear understanding of each lift to be made.
4. Signal people must place themselves where they can be clearly seen and where they
can safely observe the entire operation.

Safety
RESPONSIBILITIES OF ALL CREW MEMBERS
1. Unsafe conditions and/or practices must be corrected.

2. Obey all warning signs.
3. Watch out for your safety and the safety of others.
4. Know and understand proper machine erection and rigging procedures.
5. Alert operator and signal person of dangers, such as power lines, unstable ground, etc.
MANAGEMENT RESPONSIBILITIES
1. Operators must be competent, physically fit and, if required, licensed.

2. Operator, signal people and riggers must be trained in correct crane operation and use.
3. Operator and signal people must know standard crane signals.
4. Have a supervisor at job site responsible for site safety.
5. Crew members must be given specific safety responsibilities and be instructed to
report any unsafe conditions to supervisor.
6. Supply the weight and the characteristics of all loads to be lifted to the operator.
7. Verify that all crew members are familiar with OSHA, ANSI B30.5 requirements, state
and local jobsite requirements, as well as the instructions in manuals.
PLANNING THE JOB
1. Have a clear understanding of the work to be done.

2. Consider all dangers at jobsite.
3. Know what crew members are needed to complete the job.
4. Assign job responsibilities.
5. Establish how signal people will communicate with the operator.
6. Appoint a competent signal person.
7. Know the weight and the characteristics of the loads to be lifted.
8. Utilize rigging and other equipment which will complete the job safely.
9. Establish how equipment can be safely transported to the job site?
10. Determine how the load will be rigged.

PLANNING THE JOB
11. Determine the lift radius, boom angle and the rated lifting capacity of the crane.
12. Always pre-plan the course of each lift to determine the safest method to reach the
load’s target destination.
13. Identify the location of gas lines, power lines, or other structures and determine if the
crane or structures need to be moved.
14. Ensure that the supporting surface is strong enough to support the machine and load.
15. Establish special safety precautions, if necessary.
16. Consider the weather conditions.
17. Keep unnecessary people and equipment away from the work area.
18. Position machine to use shortest boom and radius possible.
OPERATOR SAFETY CHECK
1. Safety related items must be in place.

2. Check machine log book, to see if periodic maintenance and inspections have been
performed.
3. Ensure that necessary repairs have been completed.
4. Inspect wire rope for damage (kinks, broken wires etc.)
5. Be sure no unauthorized field modifications have been made.
6. Check for air and hydraulic oil leaks.
7. Check that all controls are in the neutral position before starting engine.
8. After starting engine, check all gauges and indicators for proper readings.
9. Test all controls.
10. Check brakes and clutches.
11. Check hoist brakes by lifting a load a few inches off the ground and holding it.
OPERATOR AIDS CHECK
Ensure that the listed items are in place and operational.

1. Boom angle indicator.

Safety
OPERATOR AIDS CHECK
2. Backup Alarms.
3. Anti-Two Block devices.
4. Overload Protection, Load Indicators, Rated Capacity Limiters.
OPERATION OVERLOAD PROTECTION
1. Know the weight and characteristics of all loads to be lifted.

2. Place the boom lifting point directly above the load when lifting.
3. The load radius will increase when the load is lifted due to boom deflection.To
compensate for the boom deflection, maintain the radius by raising the boom.
4. Know the weight of the hook and rigging, the boom and/or jib length, parts of line and
the work area.
5. Use next lower rated capacity when working at boom lengths or radius between the
figures on the rated lifting capacity chart.
6. Never lift a load without knowing whether it is within the rated capacity.
7. Never operate with anything other than recommended counterweight.
Unauthorized reduction or additions of counterweight constitute a safety hazard.
8. Do not lift loads if winds create a hazard. Lower the boom if necessary. Refer to the
Rating Chart and Operator’s Manual for possible restrictions.
9. Avoid side loading the boom.
10. Never allow the load or any other object strike the boom.
11. Loads shall be freely suspended.
OPERATION SETUP
1. Be sure the load bearing surface is strong enough to support the machine and load.
2. Be sure the crane is level. Check frequently and re-level when necessary.
3. Stay away from rotating cranes, erect barricades to keep people away. Make sure
these areas are clear before swinging.

POWER LINE SAFETY
1. Determine whether there are power lines in the area before starting any job. Only
operate around power lines in accordance with Federal, State and Local Regulations
as well as ANSI B30.5 latest edition.
2. Never remove materials from under powerlines with a crane if the boom or machine is
capable of contacting them.
3. No part of crane or load must come in contact with, or violate the minimum allowable
clearance required for operation of crane near, electrical lines.
Electrocution Hazard
Contact with electric power lines will result in death or serious injury.

Safety
POWER LINE SAFETY
Maintain Required Clearance

LINE VOLTAGE REQUIRED CLEARANCE
0 TO 50kV 10 FT ( 3.0M)
500 TO 200kV 15 FT (4.6m)
2000 TO 350kV 20FT (6.1m)
350 TO 500kV 25FT (7.6m)
500 TO 750kV 35 FT (10.7m)
750 TO 1000kV 45FT (1.37m)
>1000kV Refer to Operator's Manual
Before operating the machine, contact the electric power line owner to disconnect,
move, or insulate power lines.
4. Should contact occur, stay on crane until the boom is cleared or until the electrical
current is turned off.
5. If contact occurs, keep all personnel away from the crane. If you must leave the crane,
JUMP WITH BOTH FEET TOGETHER COMPLETELY CLEARING THE MACHINE.
Continue jumping with both feet together to leave the area.
6. Use a signal person when working around power lines.
TRAVEL
1. Care must be taken when cranes are driven (traveled) whether on or off the job site.
2. Always pre-plan the path of travel to determine the safest route to the destination.
3. A signal person shall be utilized when the operator’s vision is blocked or obstructed
during traveling operations.
4. Watch for people, power lines, low or narrow clearance, bridge or road load limits,
steep hills or uneven terrain.
5. Place the boom in the stowed position.
6. Inflate tires to specified pressure.
7. Travel slowly and avoid sudden stops and starts.
8. It is recommended that the seat belt be used during transit and travel.
9. Make sure travel surfaces can support weight of machine and any stored load.
10. Always set parking brakes when parking the machine.

OPERATIONAL AIDS - EMERGENCY PROCEDURES
When operational aids are inoperative or malfunctioning, the following requirements shall
apply for continued use or shutdown of the crane.
1. Steps shall be taken to schedule repairs immediately. The operational aids shall be put
back into service as soon as replacement parts, if required, are available and the
repairs and calibration can be carried out. “Can be carried out” does not mean, when
convenient. Every effort must be made to expedite the repairs and recalibration.
2. When a load indicator, rated capacity indicator, or rated capacity limiter is inoperative
or malfunctioning, the designated person responsible for supervising the lifting
operations shall establish procedures for determining load weights. Loads with
unknown weights shall not be lifted without a properly functioning load indicating device.
3. When a boom angle or radius indicator is inoperative or malfunctioning, radii or boom
angle shall be determined by measurement.
4. When an anti-two-block device, two-blocking damage prevention or two-block
warning device is inoperative or malfunctioning, the designated person responsible for
supervising the lifting operations shall establish procedures, such as assigning and
additional signal person, to furnish equivalent protection.
5. When a boom length indicator is inoperative or malfunctioning, the designated person
responsible for supervising the lifting operations shall establish the boom length at
which the lift will be made by actual measurement or marking on the boom.
6. When a level indicator is inoperative or malfunctioning, other means shall be used to
level the crane within the level requirements specified by the manufacturer.
In certain situations, it may be necessary to override the automatic motion limiter of the
LMI / ATB unit in order to safely operate the crane. These include but are not limited to:
The load block may lift the ATB weight before the load line can be tensioned while stowing
the boom. This will cause a motion cutout. Overriding the system, in this situation is
acceptable in order to continue to winch in slack line, securing the boom. Boom must be in
the lowered position.
If the Boom Up/Down control lever is pulled back after the boom is fully raised pressure will
be trapped in the base of the main cylinder. This will cause a motion cutout. Overriding the
system is acceptable in order to boom down enough to release the trapped pressure.

Safety
Effects of Wind Conditions

Wind Speed Detection
It is essential that you observe the permitted maximum wind speeds. To check the wind
speed, the crane can be equipped with an air speed indicator (anemometer).
This consists of two elements:
1. Rotor - fitted to the head of the main boom or main boom extension.
2. Display - on the screen. The rotational movement of the rotor caused by the wind is
converted into an electrical signal which is displayed on screen in the crane operator’s
cab. The crane operator can read off the wind speed here in m/s.
Before commencing work or erecting the equipment it must be ensured that the
anemometer is fully functional. If the values on the display change when the rotor
is rotated, the unit is functioning.
To verify functionality during conditions of no wind, the rotor should be manually
rotated.
Lifting Constraints
The crane can be used safely by following the values given in the load capacity tables up to
a wind speed of 27.8 ft/s (30 kph - force 5) on a load surface of 13 ft²/tonne.
Check the forecast and monitor wind speed conditions near the job site. When
wind speed exceeds 27.8 ft/s (30 kph - force 5), derating of the cranes lifting
capacity is required. See the cranes WARNING section of the LOAD CHART.
MAXIMUM OPERATIONAL WIND SPEED BEFORE DERATING OF LIFTING CAPACITY IS

REQUIRED.

Pay attention to the wind speed values in table below in relation to the
information in the WARNING section of the LOAD CHART. Any governmental
regulations applicable to the job site must also be observed.
Wind Force Wind Speed Consequences

Scale Terms Described mph kph Inland Territories
0 Calm 0-1 1 Calm, Smoke
rises vertically
1 Very Light 1- 3 1-5 Wind direction
indicated by the
smoke and not
by the banner
2 Light Breeze 4-7 6 - 11 The wind can be
felt on the face,
the leaves
rustle , the
banner moves
3 Gentle Breeze 8 - 12 12 - 19 Leaves and small
branches move,
banners lift
4 Mild Breeze 12 - 18 20 - 28 The wind raises
dust and leaves.
Branches move
5 Fair Breeze 18 - 24 29 - 38 Small bushes
sway. Wave
crests form on
the sea.
6 Strong Breeze 24 - 31 39 -49 Large branches
sway.
7 Strong Wind 31 - 38 50 - 61 All the trees sway

Safety
Lightning Storm
When lightning is striking in the vicinity of the crane, the operator should never attempt the
following procedures:
• Getting into the operator's cab; upper or lower, or attempting to get onto the carrier,
superstructure or boom assembly.
• If on the machine, do not try to get off the machine.
If you are in the operator’s cab (upper or lower) during an electrical storm, stay in the cab. If
you are on the ground during an electrical storm, stay away from the vicinity of the machine.

Lock Out & Tag Out
Code of Federal Regulations number 1910.147 requires that employers establish and follow
a Lock Out & Tag Out procedure and train their employees in that procedure before any
employee can operate, service or maintain any piece of power equipment.
Employers are required to make periodic inspections to see that their Lock Out & Tag Out
procedures are being followed, and they must monitor and update their program on an
ongoing basis. Employees are responsible for seeing that equipment is locked out and
tagged out in accordance with the employer's policy.
A typical Lock Out & Tag Out kit contents are illustrated in the figure below.
Typical Lock Out & Tag Out Kit
What is Lock Out & Tag Out
Lock Out & Tag Out is a procedure that's designed to prevent absolutely the unexpected or
accidental startup of equipment and to alert all workers whenever it is unsafe to operate
any piece of equipment. When used as intended, Lock Out & Tag Out also protects
personnel from energy stored in devices such as springs, accumulators, batteries,
hydraulic systems, etc.
How to Lock Out & Tag Out

• Install one or more locks to hold the master switch lever in the OFF position.
• If the switch is keyed, turn the key to the OFF position and remove the key.
• Disconnect the batteries.
• Regardless of which lockout method is used, place one or more tags on machine
control panels, access doors and electrical panels.
When is Lock Out & Tag Out required

• Any time anyone is maintaining, repairing, lubricating, or for whatever reason, working
on the equipment.
• When the equipment is broken or for whatever reason, unfit or unsafe to operate
• Whenever the equipment is left unattended.

Safety
Who must apply a lock & tag

• Any person working on the equipment.
• Foreman or other person responsible for the work being done.
• If several people are working on a machine at the same time, each person must apply
his or her own lock and tag.
When can a lock and tag be removed

After performing these six steps:
1. All safety guards are back in place.
2. All work is complete and tools are put away.
3. All workers are notified that a lock is being removed.
4. All workers are positioned safely for startup.
5. Controls are positioned for safe startup.
6. The machine is ready for safe operation.
Who can remove a lock and tag

• Only the person who applied a lock and tag is permitted to remove them.
The Lock Out & Tag Out rules laid out here are generic. To get instructions for your
particular workplace, consult your employer's Lock Out & Tag Out procedure.

Access/Egress
Access/Egress Safety
Access and egress from the crane operator's cab must always be accomplished using a three-
point system. Either two-feet and a hand or two hands and a foot should be in contact with
the crane while moving from the ground into the operator's cab or moving from the
operator's cab to the ground.
To provide safe access and egress to/from the crane, Terex provides a number of steps,
ladders and handrails allowing three--point access to all areas of the crane where it is
necessary for the operator to be when moving from the ground to the operator's cab or
from the operator's cab to the ground.
Access/egress to/from areas of the crane not accessible through the provided
three-point access devices should only be attempted using approved access
devices (ladders, lifting platforms, etc) providing three- point access capability.

Safety

Safety

Personal Safety
LOCK OUT/TAG OUT
The purpose of a Lock Out / Tag Out procedure is to ensure that the machine is isolated
from potentially hazardous energy, locked and tagged out before performing any service or
maintenance where energization, start-up or release of stored energy could cause injury.
Locate and identify all energy isolating devices and be certain which switch(es), valve(s), or
other energy isolating devices apply to the machine to be locked out. More than one
energy source (electrical, mechanical, hydraulic, etc.…) may be involved.
The Lock Out Procedure

1. Notify all affected personnel that a lockout system is going to be used and the reason.
2. If the machine is operating, shut it down following the normal shut down procedure.
3. Isolate and disconnect all machine energy sources. Stored energy (such as that in
springs, machine members, hydraulic systems, etc.) must be dissipated or restrained.
4. Lockout the machine with assigned individual lock(s). Affix a tag to the lockout device
and sign and date the tag with the name of the individual doing the work.
5. After ensuring that no personnel are exposed, and to ensure that energy sources are
disconnected, try to start the machine and engage operating controls to ensure that
the machine will not operate. Return the operating controls to the "neutral" position.
6. The equipment is now locked out.
Returning to Normal Operations

1. After service and/or maintenance has been completed and the machine is ready to
operate, check the area around the machine to ensure that no one is exposed.
2. After all tools have been removed from the machine, guards have been reinstalled, and
personnel are clear, remove the lockout device. Reconnect energy sources to restore
energy to the machine.
3. Notify all affected personnel that the machine has returned to normal operations.
For more information regarding Lock-Out/Tag-Out procedures refer to the applicable OSHA
1910.147 Standards, ANSI Standards, Federal, State, Local and Jobsite Regulations.
SLIP AND FALL PREVENTION
1. Always wait until machine has stopped before getting on and off equipment. Do not
jump on or off.

Safety
SLIP AND FALL PREVENTION
2. Do not use controls and steering wheel as hand holds.

3. Keep the machine clean and dry. Remove all oil, grease, mud, ice and snow from
walking surfaces.
4. Store all tools, rigging and other items in the tool box.
5. Replace all broken ladders or other access system components.
6. Keep non-slip surfaces in good condition.
7. Never jump off the machine. Instead, use the hand holds and step designed for
entering and exiting the machine. Face the machine and use three points of contact to
ensure your safety.

Seat Belts
SOME SUGGESTED USAGE AND MAINTENANCE INSTRUCTIONS FOR SEAT BELTS
1. Wear your lap belt low and snug.
2. Manually adjustable lap belts and shoulder harnesses are adjusted by pulling the loose
end of the webbing through the buckle or adjuster.
3. Seat belts using automatic-locking or emergency-locking retractors are self-adjusting.
4. Hand wash webbing with warm water and mild soap. Rinse thoroughly and dry in the
shade.
5. Do not bleach or re-dye, because such processing may severely weaken the assembly.
6. Inspect seat belt assemble frequently. Anytime it does not operate properly, or if there
are any defects in the webbing (i.e. torn or frayed), the seal belt must be replaced.
7. For a non-locking retractor belt, completely extend the lap belt from the retractor(s).
After adjusting the belt snugly (see # 2 above), attempt to pull additional webbing from
the retractor. If no additional webbing can be pulled from the retractor after
adjustment, then the seat belt is adjusted properly.

Assembly
Wire Rope Reeving

Reeving diagram for the main hoist line are shown. The number of parts of line used will
depend on the load to be lifted. Refer to the maximum load chart located on riding seat for
the required reeving. Hoisting and lowering speeds will be reduced as the number of parts
of line increase.
BOOM CONNECTION FOR EVEN PARTS OF LINE
1 Boom Head 3 Dead End Socket

2 Dead End Link
Use Loop Back Method for clamping dead end length of wire rope.
DO NOT SECURE THE DEAD END OF THE ROPE TO THE LIVE ROPE.
ATTACHING A DEAD END TO A LIVE LINE CAN DAMAGE, CRIMP OR PINCH
THE LIVE LINE. THIS CAN RESULT IN THE LOAD BEING TRANSFERRED TO
THE DEAD END. THIS CONDITION COULD ULTIMATELY RESULT IN THE ROPE
BREAKING UNEXPECTEDLY AT LOADS WELL BELOW THE ROPE'S NORMAL
BREAKING STRENGTH.

Assembly
MULTIPLE PARTS OF LINE EXAMPLES
A 2 Parts of Line 2 Boom Point Sheave

B 3 Parts of Line 3 Dead End
C 4 Parts of Line 4 Load Block Sheave
1 Guide Sheave

3 PART LINE
1 PART LINE 2 PART LINE
6 PART LINE
4 PART LINE 5 PART LINE
CALLOUT KEY
1. ONE PART OF LOAD A. OVERHAUL BALL
LINE
B. DEAD END ON BOOM
2. SECOND PART OF C. ONE-SHEAVE LOAD
LOAD LINE BLOCK
5 OR 6 PART OPTIONAL 3. THIRD PART OF LOAD D. DEAD END ON BLOCK
SHEAVE KIT LINE
E. TWO-SHEAVE LOAD
4. FOURTH PART OF BLOCK
LOAD LINE
F. SEE OPT. SHEAVE KIT
5. FIFTH PART OF LOAD G. THREE-SHEAVE LOAD
LINE BLOCK
6. SIXTH PART OF LOAD H. OPTIONAL SHEAVE
LINE AND SPACERS
When 5 or 6 parting the unit, take one of the spacers & top sheave out and install in the
opposite manner so both spacers are side by side and the sheave is to the outside.
If you are changing this quite often you can replace one of the spacers with optional
sheave kit T105999.
The load line should always be in the middle on the top sheave unless your are 5 or 6 parting.

Assembly
Dead Ending Wire Rope in Socket

The recommended method for the dead end of the wire rope is the Loop Back Method as
shown in figure below.
DO NOT SECURE THE DEAD END OF THE ROPE TO THE LIVE ROPE.
ATTACHING A DEAD END TO A LIVE LINE CAN DAMAGE, CRIMP OR PINCH
THE LIVE LINE. THIS CAN RESULT IN THE LOAD BEING TRANSFERRED TO
THE DEAD END. THIS CONDITION COULD ULTIMATELY RESULT IN THE ROPE
BREAKING UNEXPECTEDLY AT LOADS WELL BELOW THE ROPE'S NORMAL
BREAKING STRENGTH.

Boom Installation
DO NOT STICK HANDS OR TOOLS IN BOOM SECTIONS UNTIL THE ENGINE IS

SHUT OFF AND PTO IS DISENGAGED. SERIOUS INJURY WILL RESULT IF
BOOM IS TELESCOPED WHILE HANDS OR TOOLS ARE IN HOLES. FOLLOW
THE LOCK OUT - TAG OUT PROCEDURES CONTAINED IN THE SAFETY
SECTION OF THIS MANUAL.
1. Lift the boom into position at the turret and install the boom hinge pin.
2. Lower the boom onto the boom rest.
3. Install the topping cylinder and connect hydraulic lines.
4. Connect the hydraulic lines to the boom extend cylinder.
5. Plug or cap the end of the hoses or tubes for the winch. This step must be performed
so oil does not leak out of the lines when Step 7 is performed.
6. Adjust extension cable system. (See Boom Cable Adjustment Procedure on page 279.)
7. Once the extension cable system is properly adjusted, assemble the winch to the base
section. Tighten the mounting bolts to 280 ft.lbs.
NOTE: Step 6 is easier to perform when the winch is not installed.

8. Connect the hydraulic lines to the ports of the winch motor.
9. Install the lift cable over the sheaves of the boom tip. Be sure to pass the load line
under wire cable guides on the end of the boom sections.
10. If equipped, assemble the jib to the side of the boom.
11. Connect the anti-two block cable to the limit switch and test the anti-two block
system for proper operation.
12. Operate the winch and the telescope cylinder in both directions until all air is bled from
the system. Check the level of oil in the hydraulic tank.

Assembly
BT3870 Jib Installation

Some models are equipped with an optional side stow jib. Instructions for installing the jib
follow.
DO NOT RIDE OR CLIMB ON BOOM OR JIB. SERIOUS INJURY OR DEATH

COULD OCCUR. USE A LADDER OR SUITABLE PLATFORM TO REACH
ELEVATED PIN LOCATIONS.
JIB INSTALLATION PROCEDURE
1. Starting with a fully levelled boomtruck, fully retract the boom. Rotate the boom
to the street side of the boom rest, and lower until boom head can be reached
from the ground.

1 Chain Clevis 2 Anti-Two Block Weight
2. Remove the ANTI-TWO-BLOCK WEIGHT and CHAIN CLEVIS from wire rope
and the anti-two-block switch.
3. Remove bottom and top retainers and GUIDE PINS from sheave head.

Assembly
1 Guide Pin Locations 2 Retainer Pin
4. Remove LOAD LINE from boom head sheave and allow it to hang off the curb
side of the boom.

1 Load Line
5. Reinstall top and bottom GUIDE PINS and retainers in the sheave head.

Assembly
1 Guide Pin Locations 2 Retainer Pin
6. When the boom is fully retracted, the jib mounting holes should line up. If holes
in the jib do not line up with the holes in the boom head, readjust the boom
head by slightly extending, then fully retracting the boom. Install two PINS and
retainers from pin stow bracket, to fasten jib in place on the street side of the
boom.
1 Pin
NOTE: If any force is required to install any of the four jib pins, it should not be
more than a few hits from a machine hammer. If more force than this is required
for the first 2 pins, check alignment, it may be that the jib stowage brackets
need adjustment.
7. Remove two PINS and retainers from outer PIN STOW BRACKET.

1 Pin Stow Bracket 2 Pins
8. Raise boom to horizontal position.
JIB WILL SWING UNCONTROLLED IF BOOM IS NOT HORIZONTAL.

THERE IS A DANGER OF BODILY HARM IF THE JIB IS NOT PROPERLY
CONTROLLED.
9. Fasten a TAG LINE, approximately 15 feet long, to an ANCHOR POINT at the

end of the jib. Not all jibs have an anchor for this purpose. Use a suitable
attachment point.

Assembly
1 Anchor Point 2 Tag Line
10. Confirm jib is pinned to boom Head, then release the JIB LOCK PIN located on
the jib stow bracket with a pull and a twist, this will lock the pin in the open
position. Do not release pin until Step 6 has been completed.
DO NOT REMOVE THE JIB LOCKING PIN SECURING THE JIB TO THE
BOOM, UNTIL STEP 6 HAS BEEN PERFORMED, OTHERWISE JIB WILL
FALL OFF THE BOOM CAUSING DEATH OR SERIOUS INJURY TO
PERSONNEL AND PROPERTY DAMAGE.
1 Jib Lock Pin Location

1 Jib Stow Bracket 2 Jib Lock Pin - Unlocked
11. Extend the boom approximately 15 inches so the JIB STOW BAR is clear of the
JIB STOW BRACKET.
1 Boom Extended

Assembly
1 Jib Stow Bar 3 Jib Lock Pin

2 Jib Stow Bracket
12. Swing jib away from boom with tag line. Control movement of the jib at all
times to prevent injury and/or equipment damage.
13. Swing jib into extended position.
CONTROL MOVEMENT OF THE JIB

14. Lower the boom so the boom head can be reached from the ground if necessary.
NOTE: Avoid allowing the jib tip to come in contact with soft surfaces (i.e. dirt,
sand or gravel) as material can become wedged between jib tip sheave and
side plates.
15. Install two PINS and retainers from the pin stow bracket to fasten the jib in
place on the curb side of boom head.
NOTE: If any force is required to install the pins, it should not be more than a
few hits from a hammer. If more force is required, your jib base or boom head
may be damaged.

Assembly
1 Pin
16. Remove ANTI-TWO BLOCK SWITCH, RETAINING PIN, and PLUG from the
boom head. Install on jib head.
1 Plug 3 Anti-Two Block Switch

2 Retaining Pin Location

1 Plug 3 Anti-Two Block Switch
2 Retaining Pin
17. Remove ANTI-TWO BLOCK PLUG from base of jib and install in open
RECEPTACLE on boom head.
1 Receptacle 2 Anti-Two BLock Plug
IF THE SECOND STAGE OF THE JIB IS NOT GOING TO BE USED, SKIP TO STEP 24.
EXTENDING SECOND JIB STAGE

18. Unstow anti-two-block cable from jib base section. This is highly important to avoid
damaging the ATB cable.

Assembly
1 Anti-Two Block Cable 2 Anchor Pint

19. Raise boom to angle high enough to allow the jib to be extended without contacting
the ground.
20. Fasten a TAG LINE to a suitable ANCHOR POINT on the jib head.

21. Remove the SECOND STAGE LOCK PIN and retainer near the base of the jib.

1 Second Stage Lock Pin
22. Pull SECOND STAGE JIB out until it contacts JIB STOP PIN.
1 Tag Line 2 Second Stage Jib

23. Insert SECOND STAGE LOCK PIN into extend position and secure with retaining pin.
Push back on second stage to ensure lock pin is securing second stage.

Assembly
1 Second Stage Stop Pin 2 Second Stage Lock PIn

24. Remove ball or block from wire rope.
25. Winch out enough WIRE ROPE to reach over the sheave of the jib.

NOTE: It will be necessary to provide tension on the end of the WIRE ROPE to
prevent birdnesting of the cable around the winch drum. This can be done by
personnel, wearing heavy leather gloves.
26. Place wire rope over BOOM HEAD sheave.
27. Route cable through jib cable retainer and over jib sheave. Install WIRE ROPE GUIDE
PIN and retainer.
1 Wire Rope Guide Pin 2 Wire Rope

28. Attach ball or block to wire rope with PIN and RETAINER.

Assembly
1 Pin Retainer

BT28106 Jib Installation
Some models are equipped with an optional side stow jib. Instructions for installing the jib
follow.
DO NOT RIDE OR CLIMB ON BOOM OR JIB. SERIOUS INJURY OR DEATH

COULD OCCUR. USE A LADDER OR SUITABLE PLATFORM TO REACH
ELEVATED PIN LOCATIONS.
Jib Installation Procedure
1. Fully retract boom and lower until boom head can be reached from the ground.
1 Boom Head
2. Remove the anti-two-block weight and chain clevis from the anti-two-block
switch.

Assembly
1 Chain Clevis 2 Anti-Two Block Weight
3. Remove bottom and top retainers and guide pins from sheave head.
1 Pin
4. Remove load line from boom head sheave and allow it to hang off the side of
the boom.

1 Retainer 3 Load Line
2 Pin
5. Reinstall top and bottom guide pins and retainers in the sheave head.
6. When the boom is fully retracted, the jib mounting holes should line up. If holes
in the jib do not line up with the holes in the boom head, readjust the boom
head by slightly extending, then fully retracting the boom. Install two PINS and
retainers from pin stow bracket, to fasten jib in place on the street side of the
boom.
more than a few hits from a machine hammer. If more force than this is required
for the first 2 pins, check alignment, it may be that the jib stowage brackets
need adjustment.
7. Fasten a tag line, approximately 15 feet long, to the anchor point at the end of
the jib.

Assembly
8. Raise boom to horizontal position.

CONTROLLED.
9. Remove pin from jib pin stow bracket on boom.
1 Jib Lock Pin Location

10. Extend the boom approximately 15 inches so the jib stow bar is clear of the
front jib stow bracket at the boom head.
11. Swing jib away from boom with tag line. Control movement of the jib at all
times to prevent injury and/or equipment damage.
12. Swing jib into extended position. If it is difficult to bring the jib around you may
slightly lower the boom angle and re-attempt.
13. Lower the boom so the boom head can be reached from the ground if necessary.
NOTE: Avoid allowing the jib tip to come in contact with soft surfaces (i.e. dirt,
sand or gravel) as material can become wedged between jib tip sheave and
side plates.
14. Install two pins and retainers from the tool box to fasten the jib in place on the
curbside of boom head.
more than a few hits from a machine hammer.

Assembly
1 Jib Lock Pin
15. Remove anti-two-block switch, retaining pin, and plug from the boom head.
Reinstall on jib head.
1 Anti-Two Block Switch

IF THE SECOND STAGE OF THE JIB IS NOT GOING TO BE USED, SKIP TO STEP 20.
Extending Second Stage Jib

16. Raise boom to angle high enough to allow the jib to be extended without contacting
the ground.
17. Remove lock pin and retainer from jib.
1 Lock Pin
18. Pull second stage jib out until it contacts jib stop pin.
19. Insert jib lock pin into extend position and secure with retaining pin. Push back on
second stage to ensure lock pin is securing second stage.

Assembly
1 Lock Pin
1 Hook Ball
21. Winch out enough cable to reach over the sheave of the jib.
22. Place wire rope over boom head sheave. If machine is equipped with a sheave
retaining bracket, make sure the bracket slot is aligned with guide pin so it is held
upright. Install guide pin and retainer.
23. Route cable through jib cable retainer and over jib sheave. Install sheave pin and retainer.

1 Sheave Pin
24. Attach ball or block to wire rope with pin and retainer.
1 Hook Ball

Assembly
Changing Jib Offset
Jib Offset Pins/Holes (both sides) 4 Sheave Shaft

1 0° Pin 5 Cap Screws
2 15° Hole 6 Hoist Line Attach - Dead End
3 30° Pin
Increasing Offset
1. Retract the boom and set the outriggers.
2. Boom down to minimum boom angle.
3. Loosen the two (2) cap screws on the left side of the upper and lower sheave shafts.
This will require a 3/ 4 inch hex wrench.
4. Reeve the hoist line over the top center sheave on the boom head, around the jib
sheave, and attach to the eye on the bottom of the jib tip.
5. Winch up to take the slack out of the hoist line and to take the weight of the jib off of
the jib offset pins.
NOTE: To prevent damaging the jib, do not winch up any more than is
necessary to loosen the jib offset pins.
6. Remove the jib offset pins from the 0° offset hole and place in the 15° hole or if you
are using 30° offset then place pins in tool box.

Never Remove Either 30° Pin
7. With the engine at idle, slowly winch down to pay out hoist cable. This will lower the
tip of the jib until the jib comes in contact with the jib offset pins.
NOTE: While lowering the tip of the jib, it may be necessary to raise the boom
to prevent the tip of the jib from touching the ground.
8. Remove the hoist line from the tip of the jib and reeve the hoist line as needed.
Decreasing Offset
Reverse above procedure to return jib to 0° offset position.

Description Of Machine and Controls
Outrigger Controls
With the arm mounted Outrigger Control box, the Terex Cranes Boom Truck Main and
Auxilary outriggers can be operated from either station by swinging the arm from side to side.
1. OUTRIGGER EXTEND / RETRACT SWITCH - Use in combination with #2, #3, #4 or #5

rocker switches. Press left to activate extend, press right to activate retract on the
selected outrigger.
2. OUTRIGGER SELECTION SWITCH - CURBSIDE FRONT - Use in combination with #1
rocker switch. Press left to activate the jack cylinder, press right to activate the
outrigger beam.
3. OUTRIGGER SELECTION SWITCH - CURBSIDE REAR - Use in combination with #1
rocker switch. Press left to activate the jack cylinder, press right to activate the
outrigger beam.
4. OUTRIGGER SELECTION SWITCH - STREETSIDE FRONT - Use in combination with
#1 rocker switch. Press left to activate the outrigger beam, press right to activate the
jack cylinder.

5. OUTRIGGER SELECTION SWITCH - STREETSIDE REAR - Use in combination with #1

rocker switch. Press left to activate the outrigger beam, press right to activate the jack
cylinder.
6. OUTRIGGER FULLY EXTENDED INDICATOR LIGHT - CURBSIDE REAR - When
outrigger beam is fully extended in the horizontal direction the indicator light will
illuminate "GREEN".
7. OUTRIGGER FULLY EXTENDED INDICATOR LIGHT - STREETSIDE REAR - When
outrigger beam is fully extended in the horizontal direction the indicator light will
illuminate "GREEN".
DO NOT OPERATE OUTRIGGERS WITHOUT DETERMINING CLEARANCE

FROM OBSTRUCTIONS OR PERSONNEL.
BOTH INDICATOR LIGHTS #6 & #7 NEED TO BE ILLUMINATED PRIOR TO

PERFORMING ANY CRANE LIFTING OF LOAD.

Power Take-Off
There are several styles of PTOs used on various equipment. Refer to the following pages
for operation on PTO operation for Cable PTO, Air PTO, and Electric over Hydraulic PTO.
CABLE ACTIVATED
The PTO/Pump control is located on the floor to the right of the driver’s seat.. The PTO is
engaged when the knob is pulled out and disengaged when the knob is pushed in. The
truck gear shift must be in the neutral position when the PTO is to be engaged. The
indicator on the dash will be lit when the PTO is engaged.
The parking brake must be firmly set before leaving the cab to begin operation. If the
ground surface is icy, slick or sloped you will be required to help stabilize the truck with
wheel chocks.
Disengage PTO before driving truck. Failure to do so will cause damage to the
transmission and hydraulic pump.
1 Indicator Light

1 PTO Control
AIR ACTIVATED
The PTO/Pump control is located on the center of the dash.. The PTO is engaged when the
upper end of the switch is depressed and disengaged when the lower end of the switch is
depressed. The truck gear shift must be in the neutral position when the PTO is to be engaged.
wheel chocks.
Sterling
1 PTO Control

Peterbilt
1 PTO Control
ELECTRIC ACTIVATED
The PTO/Pump control is located in the center of the upper-right switch panel on the dash.
The PTO is engaged when the upper end of the switch is depressed and disengaged when
the lower end of the switch is depressed. The truck gear shift must be in the neutral
position when the PTO is to be engaged.
wheel chocks.
1 PTO Control
PTO Applications
The following table identifies in which model a particular PTO/Pump Control system may be
installed.

MODEL (>)/ BT3870 BT28106

PTO TYPE (V)
CABLE ACTIVATED X
AIR ACTIVATED X
ELECTRIC ACTIVATED X X

Controls
With the dual operator control stations the Terex Cranes Stinger can be operated from
either side of the unit. The controls on the console are: Boom Swing, Telescope,Hoist and
Boom Raise. Engine Start/Stop, Outrigger System and Signal Device. All controls and
direction of actuation for desired movement are identified by the information placards
mounted on top of the control console or control knobs.
BT3870 Control Panel
NOTE: Machine has dual control stations. Controls shown are right side. Left side
controls are identical. (Except test ports)
1. SIGNAL DEVICE
2. ENGINE START/STOP SWITCH
3. LEVEL
4. HOUR METER
5. HYDRAULIC TEST PRESSURE PORTS
6. SWING
7. BOOM TELESCOPE
8. WINCH
9. BOOM HOIST
10. EMERGENCY STOP
11. WINCH SPEED SWITCH

BT28106 Control Panel
NOTE: Machine has dual control stations. Controls shown are right side. Left side
controls are identical. (Except test ports)
1. SIGNAL DEVICE
2. ENGINE START/STOP SWITCH
3. LEVEL
4. HOUR METER
5. HYDRAULIC TEST PRESSURE PORTS
6. SWING
7. BOOM TELESCOPE
8. WINCH
9. BOOM HOIST
10. EMERGENCY STOP

11. WINCH SPEED SWITCH
12. BUMP THROTTLE SWITCH
1. SIGNAL DEVICE - Push button to sound truck horn as an audible signal to

warn other personnel in the area.
2. START/STOP SWITCH - Depress the upper end of the rocker switch to start
engine, depress the lower end of the rocker switch to stop engine.
3. LEVEL - Use outriggers to make sure bubble is centered and machine is level
prior to making a lift.

4. HOURMETER - Indicates machine hours.
5. HYDRAULIC TEST PRESSURE PORTS - Attach portable pressure gauge to

test relief settings.

5A SWING TEST PRESSURE PORT 5C BOOM TEST PRESSURE PORT
5B WINCH TEST PRESSURE PORT
6. SWING - Push lever to rotate boom counterclockwise, pull lever to rotate boom
clockwise.
7. BOOM TELESCOPE - Push lever to extend boom, pull to retract boom.

8. WINCH - Push lever to lower load line, pull lever to raise load line.
NOTE: Combined flow speed increase will be triggered at the limit of travel for
both raise and lower.
9. BOOM HOIST - Push lever to lower boom, pull lever to raise boom.
Frequent use of combined flow 2-speed winch will cause hydraulic oil to
overheat. Functions may stop and hydraulic components may be damaged.
NOTE: Controls must be used together to achieve combinations of movements.

For instance, the boom extension and loadline (hoist) must be used together to
maintain clearance between boom tip and downhaul weight.
10.
EMERGENCY STOP - Push to stop engine in case of emergency. Rotate clockwise to

release button to allow machine to be started again.

11.
WINCH 2-SPEED SWITCH - (Motor-Shift 2 Speed option only) Depress the upper end
for fast, Depress the lower end for slow.
12.
BUMP THROTTLE SWITCH (BT28106)

• With the PTO on, the idle is 800 rpm (700 rpm when the PTO is off). The truck will
idle with the switch off.
• The bump throttle is a two position switch, off or on.
• When the switch is on the number of times it is turned off is the speed setting it
will go to.
• Turning the switch on-off-on in rapid secession will bring it to speed one.
• Turning the switch on-off-on-off-on will bring the truck to speed two.
• While in speed two, turning the switch off and back on will bring the truck back to
speed one.

• Once again: the number of times the switch is turned off after it has been turned
on will determine the speed setting.
• Idle: 800 rpm
• Speed one: 1100 rpm
• Speed two: 1610 rpm
13.
ACCELERATOR (BT3870) - Foot operated, with factory adjusted stop for maximum
pump speed of 2,000 to 2,200 R.P.M.
ACCELERATOR (BT28106)- Foot operated, with factory adjusted stop for maximum
pump speed of 2,300 to 2,350 R.P.M.
NOTE: This foot-operated throttle control is optional for BT28106

Front Stabilizer
1. FRONT BUMPER STABILIZER - Push switch down to extend outrigger, pull switch up to
retract.
FRONT STABILIZER MUST BE USED WHEN WORKING/LIFTING OVER THE

FRONT OF THE TRUCK.
DO NOT OPERATE OUTRIGGERS WITHOUT DETERMINING CLEARANCE

FROM OBSTRUCTIONS OR PERSONNEL.
THE FRONT BUMPER OUTRIGGER MUST BE THE LAST OUTRIGGER TO BE

EXTENDED AND THE FIRST OUTRIGGER TO BE RETRACTED.
1 Front Stabilizer Switch

Winch Inching Valve Switch

1. WINCH INCHING VALVE - lift switch cover to acces switch. Press switch up to activate
winch up, press switch down to activate winch down

Rated Capacity Indicator and Anti-Two Block
Rated Capacity Indicator System
The Terex boom truck is equipped with the Greer Insight Rated Capacity Indicator System.
The operator is provided with a continuous readout of rated capacity, approach to
overload, and two-block condition. Refer to the Greer operation and setup manual, located
in back of this manual, for proper maintenance and setup of unit.

Anti-Two Block Components

CABLE REEL
The anti-two block cable is wound onto a spring loaded cable reel which is bolted to the
left side of the boom base. The reel allows the cable to pay-out and pay-in as the length of
the boom is changed. The cable reel has slip rings which allow electric current to flow even
while the reel is turning. This cable and reel assembly is also used to measure boom
extension when the boom truck is fitted with a loadmoment sensing/indicating system.
The Greer Insight is designed as an aid. Refer to Maximum Load chart for proper
areas of operation.
LIMIT SWITCH
An anti-two block switch is mounted on the left side of the boom tip. The switch is normally
open. During operation the switch is held closed by a counterweight suspended from the
switch lever by a chain. The closed limit switch allows current to close the relay in the
junction box in the mainframe. When the load block (or downhaul weight) is lifted too high,
it will lift the counterweight. This action will cause the limit switch to open, breaking the
circuit to the relay. This, in turn, de-energizes the coil on the unloader block assembly.
BT3870 Anti 2-Block Components
1 2-Block Wire 5 2-Block Chain

2 2-Block Reel 6 2-Block Weight
3 Sheave Assembly 7 2-Block Wire (to Electrical Box)
4 2-Block Switch

BT28106 Anti 2-Block Components
1 Reel Assembly Greer 4 3B6 Assembly Display

2 Pressure Sensor 5 3B6 Switch (Hoist Limit)
3 3B6 Harness 6 3B6 Counter Weight
UNLOADER FOR RCI PARTS GROUP

The unloader valve solenoid manifold is located on top of the console assembly, under the
swing drive cover. The valve contains two electrically operated solenoids. The RCI solenoid
valve will operate to either contain or unload a pilot signal. (Note: the other solenoid is
exclusively for the 2-speed winch.) When the RCI solenoid is energized, it is closed and no
oil is permitted to pass through the valve. There are three check cartridges in the top of the
valve to prevent inter-feed between the other functions feeding into the block (boom
extend, winch up, and boom down.) The 2-speed winch solenoid is also isolated to prevent
interference with the boom functions.
The function of “unloading” oil is done by a pilot operated cartridge referred to as a ported
anti-void. These anti-void valves are located on the boom and winch control valves. The anti-
void separates the work oil from the tank passage in the boom control valve. An orifice in
the anti-void allows it to pressure balance. When the solenoid on the anti-two block
unloader is opened, oil starts to flow across the orifice in the anti-void and the oil can get
out faster than it can get in. This creates a pressure drop and allows the anti-void to open,
routing the function oil to tank. See this page for the console components location chart.

Unloader for RCI Parts Group
1 Unloader Valve 4 To Drain Manilfold

2 Solenoid Coils 5 Boom Valve
3 Unloader Ports 6 Winch Valve

Inspection
Suggested Hydraulic Crane Inspection Checklist

This check list is to be used in addition to the information provided in this manual to
properly operate and maintain the machine.
Table 1:
ITEMS TO BE INSPECTION SATISFACTOR ADJUST REPAIR

INSPECTED & CODE Y
CHECKED
VISUAL INSPECTION H D
(Complete Machine)
OVERALL D
CLEANLINESS
HYDRAULIC SYSTEM D
(Leaks or Damage)
AIR SYSTEM (Leaks or D
Damage)
HYDRAULIC FLUID D
TRANSMISSION FLUID D
LEVEL
ENGINE CRANKCASE D
FLUID LEVEL
FUEL TANK FLUID D
LEVEL
RADIATOR FLUID D
LEVEL
MACHINE D
LUBRICATION
ATTACHMENT PIN D
BOLTS
MUFFLER/EXHAUST D
SYSTEM
H Inspect OVERALL machine (including carrier) for cracks, weld separation, leaks,
damage, vandalism.
INSPECTION CODE D - DAILY M - MONTHLY W - WEEKLY S - SEMI-
INTERVALS ANNUALLY
NOTES:
1. Indicate inspection result by checking in the satisfactory, adjust, or repair boxes provided.
2. When appropriate, enter your diagnosis on back of page for repairs or adjustments made.

Inspection

INSPECTED & CODE Y
CHECKED
ALL CONTROL D
MECHANISMS
INSTRUMENT D
GAUGES
CLUTCHES & BRAKES D
WIRE ROPE, SHEAVES D
& GUARDS
TWO BLOCK DAMAGE D
PREVENTION SYSTEM
LOAD SUPPORTING D
COMPONENTS
CONDITION
FIRE EXTINGUISHER D
BACKUP ALARM D
BOOM ANGLE D
INDICATOR
HEAD/TAIL/BRAKE D
LIGHTS & 4 - WAY
FLASHERS
HORN D
CABLE SPOOLING D
PROPERLY
WEDGE SOCKETS D
AXLE FLUID LEVEL W
SWING REDUCER W
FLUID LEVEL
DRIVE SHAFTS & U W
JOINTS
damage, vandalism.
INTERVALS ANNUALLY
NOTES:

INSPECTED & CODE Y
CHECKED
TIRE & WHEEL W
CONDITION &
INFLATION PRESSURE
AIR REGULATORS W
AIR CLEANER W
ELEMENT
CLUTCH & BRAKE W
LINKAGE & PINS
WHEEL LUG NUT W
TORQUE
FAN BELT TENSION W
STRUCTURAL W
MEMBERS & WELDS
BOOM INSPECTION W
BATTERIES & M
STARTING SYSTEM
ALCOHOL M
EVAPORATOR
SWING BEARING S
BOLT TORQUE
MACHINERY GUARDS S
LOAD CHART & S

SAFETY WARNINGS
damage, vandalism.
INTERVALS ANNUALLY
NOTES:

Inspection
Wire Rope Inspection

Safe operation of your Terex Cranes Boom Truck is dependent on the proper use of wire
rope in all operations. The ideal situation is to remove a wire rope from service after
receiving maximum service life, but without sacrificing safety. The end point of useful
service life is determined by regular inspections of the wire rope by competent personnel.
OSHA and other agencies having jurisdiction, issue instructions governing the inspection of
wire rope used on special equipment and in specified industries. All wire rope users are
urged to comply with the law for their particular situation. Inspections must be carried out
at stated intervals. When the data obtained from these inspections indicates that the
strength of the wire rope has appreciably decreased, and that further use would constitute
a safety hazard, the rope must be removed from service. It is the responsibility of the user
to know what codes apply to his situation and to comply with their requirements.
In the interest of safety, Terex Cranes believes that any wire rope, where failure might
endanger personnel, equipment, or the load, must be removed from service when any of
the listed conditions are detected. We recommend a daily visual inspection of the entire
length of rope, and a thorough inspection at least once per month - including a full written
report that is dated, signed, and kept on file. The following conditions for removal of a wire
rope from service should be regarded as a guide, with any specific regulations covering
your equipment and industry taking precedence.
1 One Rope Lay Length 3 One Wire

2 Core 4 One Strand
1. Six broken wires in one rope lay or three broken wires in one strand in one rope lay.
One rope lay is the linear distance, measured along the rope, required by a strand to
make one 360° turn around the axis.
2. Wear of 1/3 of the original diameter of outside individual wires.
3. Kinks, crushing, cuts, unstranding, or any other damage resulting in distortion of the
rope structure, are cause for removal of rope from service.
4. Heavy rusting, corrosion, pitting, or any evidence of burning, are cause for removal.
5. Any reduction in rope diameters below nominal, for any reason, should be evaluated.
A reduction in diameter of more than the following is cause for removal of the rope
from service:

1/64” For rope diameters up to and including 5/16”
1/32” For rope diameters 3/8” through 1/2”
3/64” For rope diameters 9/16” through 3/4”
1/16” For rope diameters 7/8” through 1 1/8”
3/32” For rope diameters 1 1/4” through 1 1/2”
REDUCTION OF WIRE ROPE DIAMETER

Operating Instructions
Job-Site
Job Site Setup Procedure
1. Position vehicle on solid level ground, fully set parking brake, and place transmission
in neutral.
2. Engage pump PTO. Allow hydraulic oil to warm up by circulating to prevent pump
damage. NEVER DRIVE VEHICLE WITH PUMP PTO ENGAGED.
3. Check hydraulic system filter indicator to confirm that filter is functioning properly.
4. Extend all outriggers to firm contact with solid level surface, and level vehicle. Raise
the crane only enough to take the weight off the front tires.
5. Always pay out winch line before extending boom. Failure to do so will result in the
load block contacting the anti-two block switch which will shut down the boom extend
function or damage the crane.
6. Always know your operating radius (distance from centerline of rotation to load hook),
and the actual weight of load being lifted. Load radius may vary at different rotation
positions.
7. Operation ahead of the main outriggers requires the use of an optional front bumper
stabilizer. The least stable boom position is immediately ahead of the mainframe
outriggers over the truck cab.
8. Consult manual for cold weather operation.

Outrigger Positioning
Before conducting any boom operation you must extend all outriggers to a firm and level
surface. In the event that other conditions exist such as: loose or sandy soil, crusty or frosty
surface with soft soil underneath, icy or slick pavement, sloping surfaces, etc., you will be
required to restrict your operations. In some areas, you may be able to level your crane with
the use of outrigger pads or blocks. These pads must be made of adequate material and
should not exceed 2 inches in thickness. If the main outriggers can not be placed at or near
the same level as the wheels, the outrigger spread will be affected. THis can result in
damage to the crane and/or instability.
OUTRIGGER POSITIONING - FOR LOAD HANDLING OVER SIDE OR REAR OF UNIT

The main outriggers should be extended first, then the auxiliary stabilizers. Optional front
bumper stabilizer (if equipped) must be extended last. Raise the unit just enough to take all
weight off the truck suspension. The front tires should remain in contact with or close to the
ground when the unit is setup and leveled. Fully raising the main outriggers slightly reduces
their spread, reducing stability.
OUTRIGGER POSITIONING - FOR LOAD HANDLING OVER FRONT OF UNIT

The main outriggers should be extended first, then the auxiliary stabilizers. Front bumper
outrigger is required for lifting over the front of the unit and must be extended last. The
front tires should remain in contact with or close to the ground when the unit is setup and
leveled. Fully raising the main outriggers slightly reduces their spread, reducing stability.
When the load is being handled over the front of the truck, the front outrigger must be
extended.
TO PREVENT STRUCTURAL DAMAGE TO THE CARRIER CHASSIS - THE

OPTIONAL FRONT BUMPER STABILIZER (IF SO EQUIPPED) MUST BE
EXTENDED LAST AND RETRACTED FIRST.
OBSERVE CAUTION NOTES ON OUTRIGGER MOVEMENT WHENEVER

SETTING UP OR STOWING OUTRIGGERS.

Work Site Position
The best possible work site should always be sought when you are positioning the crane.
An ideal location is where the ground is firm, level and dry. The crane should be situated in
close proximity to the work area. The site should be free of overhead obstructions. Maintain
safe clearances from electrical power lines and apparatus. You must allow for boom and
platform sway, rock or sag, and electrical line and load line swaying.

Cold Weather Operation

During cold weather operation the operator must allow the oil to warm up to operating
temperature. This can be accomplished by allowing the hydraulic pump to run under no
load for ten minutes at low engine speed. Next, actuate all the controls slowly until controls
move smooth and easy. In extreme cold, extra care must be taken to avoid any impact
loading. Materials which are normally ductile can become brittle at extreme cold
temperatures.
FAILURE TO ALLOW OIL TO WARM UP MAY CAUSE DAMAGE TO PUMP AND

SLOW RESPONSE TO FUNCTION CONTROLS.

General Operational Issues
General Rules
1. Always operate controls to lower the load line while extending the boom. This will
maintain clearance between boom tip and downhaul weight.
2. Make certain load line is not twisted or kinked, and that load line is properly seated on
drum and in sheaves.
3. During winching, meter all controls and apply power smoothly - no sudden starts or
stops.
4. When hoisting a load, raise it a few inches and allow controls to return to neutral to
determine if winch brake and boom holding valves are working properly.
5. You must not make side pulls with the boom. This type of loading can damage the
boom and rotation mechanism. Do not raise or lower a load in such a manner that
would cause side loading.
OBSERVE CAUTION NOTES ON OUTRIGGER MOVEMENT WHENEVER

SETTING UP OR STOWING OUTRIGGERS.
6. When lifting a load, you must always make certain that three (3) full wraps of rope
remain on winch drum at all times. Maintain tension on the load line at all times to
prevent rope from becoming twisted or kinked and to keep cable properly seated on
drum and sheaves. When lifting loads that exceed the single part line limitation shown
on your maximum load chart, consult chart instructions on how to multipart the load line.
WHEN USING A MULTIPART LOAD LINE, BOOM EXTENSION MUST BE

LIMITED TO MAINTAIN (3) FULL WRAPS ON WINCH DRUM.
7. The proper maintenance and care of the wirerope load line on your Terex Cranes
boom truck is most important. Refer to standard ANSI/ ASME B30.5 for wire rope
inspection and maintenance procedures as well as special provisions for handling
maximum rated loads with rotation resistant ropes. A rope inspection record is
provided in the maintenance manual.
8. Load line loop and drum wedge must be properly seated inside winch drum before
winding load line on winch drum. Refer to maintenance and installation manuals for
instructions.

1 Load Line 3 Three Wraps Minimum

2 Drum Wedge

Safety Devices
The safety devices on your Terex Cranes Boom Truck are described below. These devices
will help you maintain control of a load should power or hydraulic line failure occur. You
must understand the function and operation of these devices so that a continual check on
their performance can be made.
SHOULD ANY OF THESE DEVICES FAIL TO FUNCTION, STOP ALL

OPERATIONS AND CONSULT YOUR AUTHORIZED TEREX CRANES DEALER.
THIS CRANE CAN BE OVERLOADED BY AN OPERATOR WHO FAILS TO
FOLLOW THE INSTRUCTIONS CONTAINED IN THIS MANUAL.
BOOM LIFT CYLINDER HOLDING VALVE
A single acting holding valve is cartridge-mounted in the cylinder base. This valve holds the
boom in the elevated position should power or hydraulic pressure line failure occur. Should
any of these happen, “STOP NOW.” If the boom creeps down, consult your authorized
Terex Cranes dealer.
NEVER, UNDER ANY CIRCUMSTANCES, REMOVE OR ATTEMPT TO REMOVE

THE CARTRIDGE FROM THE LIFT CYLINDER BASE UNTIL AN AUTHORIZED
MAINTENANCE PERSON IS PRESENT AND THE BOOM IS PROPERLY
SUPPORTED AND BLOCKED. AN UNSUPPORTED BOOM CAN FALL
UNCONTROLLED; CAUSING DEATH OR SERIOUS INJURY OR PROPERTY
DAMAGE.
EXTENSION CYLINDER HOLDING VALVE
A holding valve is mounted to the cylinder rod end (boom base) for 2nd and 3rd stage
extension (also 4th stage, if applicable). This valve holds the cylinder in the extended
position should power or hydraulic pressure line failure occur. If the boom creeps in under
load, consult your authorized Terex Cranes dealer.
OUTRIGGER CYLINDER HOLDING VALVE
All outriggers are equipped with internal cartridge type lock valves. If outriggers creep up
under load, or down while roading, consult your authorized Terex Cranes dealer.
WINCH SAFETY BRAKE
To determine if the brake is working, set the outriggers, raise a load a few feet and release
control handle. Shut truck engine off; actuate winch control handle in down direction. If the
load creeps down, consult your authorized Terex Cranes dealer.
SWING DRIVE BRAKE (ROTATION GEARBOX)
The rotation gear drive has a spring-applied hydraulic release brake. To determine if the
brake is working, set the outriggers, swing the boom and release the control handle. If the
boom continues to swing, consult your authorized Terex Cranes dealer.

Training and Operator Qualifications

It is extremely important that you have a thorough knowledge of all the operating
characteristics of your crane. This crane will not be safe if improperly used! Crane operation
shall be limited to personnel with the following minimum qualifications:
1. Designated, competent and experienced persons. If required, a valid certification for
operation must be on file.
2. Trainees or untrained persons under direct supervision of qualified persons.
3. Maintenance and test personnel, only if it is necessary for the performance of their duties.
4. Supervisors with a designated experienced person present.
Operators and trainees will meet the following qualifications:

1. An operator shall be physically and mentally capable of operating the unit.
2. Demonstrate ability to read and comprehend all placards, operator’s manuals, codes,
and other information pertinent to correct and safe crane operation.
3. Operator shall demonstrate to employer the ability to operate specific type of
equipment or provide satisfactory evidence of qualifications and experience to do so.
4. Recognize and be responsible for all maintenance requirements of the crane operated
by him/her or trainees under supervision.
5. If an operator becomes physically or mentally unfit, they shall disqualify themselves.

Operator Aids
ANTI-TWO BLOCK
The anti-two-block system will sense the presence of the load block in close proximity to
the boom tip and will automatically interrupt the operation of those boom functions which
could bring the load block in contact with the boom tip. A warning horn will sound to alert
the operator to the two-block condition.
Those boom functions which could be used to move the load block further from the boom
tip will remain operational.
DO NOT RELY ON THE ANTI-TWO BLOCK DEVICE AS A WINCH HOIST STOP.
OUTRIGGER WARNING ALARM

The outrigger warning alarm will sound an audible signal whenever any outrigger leg is moving.
LOAD INDICATING EQUIPMENT ON THIS CRANE IS INTENDED ONLY AS AN

AID TO SAFE OPERATION.
LOAD/RADIUS INDICATING ELECTRONICS SHOULD NOT BE RELIED UPON TO
REPLACE THE USE OF CAPACITY CHARTS AND PROPER OPERATING
PROCEDURES.
RATED CAPACITY INDICATOR (Greer Insight)

This system is designed to provide the operator with information on the load he/she is
lifting and also help prevent overloading of the crane. In order for this system to be
effective, the operator must read and understand the instructions contained in this manual.
When limits are reached, an overload warning is activated. At the same time, the crane
movements that would increase the overload condition - such as hoist up, telescope out,
and boom down will be stopped.
To reset the rated capacity indicator system telescope in, winch down, or boom up.
If the RCI system must be overridden for any reason, the “Cancel Alarm” button on the face
of the rated capacity indicator display unit should be depressed for 5 seconds. At this point
the system is overridden until the overload or anti-two-block condition is removed. See the
RCI system manual at the end of this book for more detail.
ABUSE OR MISUSE OF THE ANTI-TWO-BLOCK/ RCI OVERRIDE CAN RESULT

IN DEATH, SERIOUS INJURY, OR PROPERTY DAMAGE.

Load Handling Operations

Before moving a load, you must study the capacity placards carefully and adhere the load
capacities and radii of operation given. During operations when lifting, swinging, or
extending the load, the controls should always be metered when beginning or terminating
movement to prevent sudden starting or stopping which imposes undue shock loads on
the equipment. This is especially true when handling heavy loads and in extreme cold
temperatures. Note that the least stable position for a standard mount (crane behind cab) is
usually over the front of the truck. The optional front bumper mounted stabilizer must be
used to lift in front of the main outriggers.

Max. Load and Boom Angle Charts
Using the Maximum Load Chart
The maximum lift capacity chart shown on the following page is located on either side of
the Main Frame. Their purpose is to show you the maximum capacities at various radii. The
boom lengths match the markings on the sides of the boom second section.
The boom angle indicators display the boom angle and are located on the base boom just
above the operator’s station.
The boom extension is synchronized so the operator has only to observe which number is
showing on the second stage. By using this boom extension and reading the boom angle
off the boom angle placard, the operator can determine the approximate operating radius
and by using the maximum load that can be lifted if that radius is maintained.
360° OPERATION REQUIRES THAT A FRONT BUMPER STABILIZER IS

INSTALLED AND PROPERLY SET.
The following is an example of how to use the load chart: (Sample load chart on following
page):
1. Assume you have extended the boom until the 53’ mark is exposed on the second
boom section.
2. Using the boom angle indicator as your guide, you have raised the boom to 40° elevation.
Using the range diagram section of the maximum load chart, find the 40° angle line and
follow it to the 53’ arc. Then follow the vertical line down; the operating radius is
approximately 40’.
Using the Load Rating section of the load chart, go across the top of the chart (boom
length) to the 53’ column and go down (operating radius) to 40’ the number to the
immediate right is the maximum load that can be lifted (i.e. 4,700 lbs.).
Since the boom will deflect as it is loaded the boom angle will have to be increased to
maintain a loaded boom radius of 40’. If the boom is not raised up above 40° before lifting
the load - the load will swing out, increasing the operating radius. This may cause an
overload condition.
NOTE: In an occurrence where the operating radius is between those listed on the
chart, use the smaller lift capacity. When the boom length is between those listed,
use the smaller lift capacity.
It is important that you know the weight of any material that you attempt to
handle. This can be determined by use of a dynamometer or scales.
The maximum lift capacity chart shows the maximum lifted load. Maximum load is the
weight of the material being handled plus such load handling equipment as slings, buckets,
downhaul weights, etc. The weight of load handling equipment must be deducted from the

maximum load rating to determine how much payload you can lift. In cases where the
optional jib is stowed on the base boom, the appropriate stowed jib deduction (shown at
the bottom of each boom length increment) must be subtracted also.
Sample BT3870 Load Chart

Swinging of a suspended load can cause the load to drift away from the crane.
The drifting of the load away from the crane will increase the cranes operating
radius. The increase in operating radius may cause the crane to tip or the boom
to fail.
Bouncing or jerking of a load will cause shock loading to many critical parts of
the crane. The shock loads may cause these critical parts to fail.

Operating Radius
1 Center Line of Bearing 3 Load Radius

2 Center Line of Load

Boom Angle Placards
CAUTION - Do not extend jib into this area unless boom is fully retracted.

Operating the Unit

Operating the Unit
Now that you are familiar with the controls and function of the Terex Cranes Boom Truck,
practice making some typical job applications. As with any piece of equipment, practice is
required to develop the coordination and knowledge necessary for smooth and efficient
operation.

Initiating Operation
1. If possible, position the unit at the job site in such a manner as to assure all work
operations can be performed without repositioning the truck (see Work Site Position
on page 117). However, strict observance of load weight, radius and maximum load
rating must always be complied with.
2. Set parking brake securely.
3. Place transmission in neutral and engage PTO.
4. Extend all outriggers to make firm contact with ground. (See Outrigger Positioning on
page 116.) Provide outrigger pads if terrain is soft or if outriggers tend to sink into
ground. Properly level the machine using the console mounted bubble level.
IF UNIT IS EQUIPPED WITH OPTIONAL FRONT BUMPER MOUNTED

STABILIZER, IT MUST BE EXTENDED LAST TO PREVENT STRUCTURAL
DAMAGE.
While operating the crane, frequently check that proper level condition is maintained.
NOTE: Console mounted bubble levels must be periodically checked for proper
adjustment. See Maintenance manual for more information.
5. Position yourself at the operator’s console and accelerate the truck engine to desired
speed. Maximum pump speed should not exceed 2,300 R.P.M.
6. Bring the hydraulic oil up to operating temperature. (See Cold Weather Operation on
page 118.)
7. Check all controls for proper operation. During all operations, the controls should be
metered to prevent sudden starting and stopping.
FAILURE TO METER YOUR CONTROLS INDUCES HIGH SHOCK LOADS ON

THE EQUIPMENT WHICH MAY RESULT IN STRUCTURAL FAILURE OR
OVERTURNING OF THE CRANE.
DEATH OR SERIOUS INJURY MAY RESULT.

Arm and Hand Signals
HOIST. With LOWER. With USE MAIN USE WHIPLINE. RAISE BOOM.
forearm vertical arm extended HOIST. Tap fist (Auxiliary Hoist) Arm extended,
fore finger downward, on head; then Tap elbow with fingers closed,
pointing up, forefinger use regular one hand, then thumb pointing
move hand in pointing down, signals. use regular upward.
small horizontal move hand in signals.
circles small horizontal
circle.
LOWER BOOM. MOVE SLOWLY. RAISE THE LOWER THE SWING. Arm
Arm extended, Use one hand to BOOM AND BOOM AND extended, point
fingers closed, give any motion LOWER THE RAISE, THE with finger in
thumb pointing signal and place LOAD. With arm LOAD. With arm direction of
downward. other hand extended, thumb extended, thumb swing of boom.
motionless in pointing up, flex pointing down,
front of hand fingers in and out flex fingers in
giving the motion as load and out as long
signal. (Hoist movement is as load
slowly shown as desired. movement is
an example.) desired.

STOP. Arm EMERGENCY TRAVEL. Arm DOG TRAVEL.(Both
extended, palm STOP. Both extended EVERYTHING. Tracks.) Use
down, move arm arms extended, forward, hand Clasp hands in both fists in front
back and forth palms down, open and slightly front of body. of body, making
horizontally. move arms back raised, make a circular motion
and forth pushing motion about each
horizontally. in direction of other, indicating
travel. direction of
travel, forward or
backward (For
land cranes only.)
TRAVEL. (One EXTEND BOOM. RETRACT EXTEND BOOM. RETRACT

Track) Lock the (Telescoping BOOM. (Telescoping BOOM.
track on one side Booms.) Both Telescoping Boom.) One (Telescoping
indicated by fists in front of Booms.) Both Hand Signal. Boom.) One
raised fist. Travel body with fists in front of One fist in front Hand Signal.
opposite track in thumbs pointing body with of chest with One fist in front
direction outward. thumbs pointing thumb tapping of chest, thumb
indicated by toward each chest. pointing outward
circular motion other. and heel of fist
of other fist, tapping chest.
rotated vertically
in front of body.
(For land cranes
only.)

Lifting the Load

Follow recommended procedures for work site position, outrigger positioning, and control
metering.
Always inspect downhaul weight, load line, hook and/ or any load handling equipment for
damage or excessive wear before use.
The following general instructions should be adhered to each time a lifting operation is
performed.
IT IS IMPORTANT THAT YOU KNOW THE WEIGHT OF ANY MATERIAL THAT

YOU ATTEMPT TO HANDLE. THIS CAN BE DETERMINED BY USE OF A
DYNAMOMETER OR SCALES.
STEPS TO LIFTING A LOAD

1. Determine what the total load weighs.
NOTE: Total load includes the weight of the material being lifted plus any
material handling devices such as slings, yokes, personnel platforms, load
blocks, jib deducts, etc.
2. Consult the maximum load chart on your crane and determine the correct boom
radius and parts of line required based upon your load weight using 3B6 for BT28106.
3. Check the configuration setting number for the Greer Insight RCI - It must match the
actual crane configuration (Including parts of line rigged).
4. Rotate the boom tip until it is directly over the material to be lifted. Unless continuous
rotation is specified, Terex Cranes Boom Trucks are equipped with 370° rotation
stops. It is important that you be aware of the position of the stops before lifting in
order to assure maximum rotation and prevent excess handling of the load. The stops
are generally over the front of the truck.
5. Attach load line to material and begin operation. Observe proper sling or chain usage
and make sure any load handling attachment used has adequate size and capacity for
the load being lifted.
6.
THE RATED CAPACITY INDICATOR SYSTEM DOES NOT PROTECT THE CRANE
WHEN THE BOOM IS OPERATED BELOW HORIZONTAL.
Observe position of boom and load at all times. The rated capacity indicator system
does not protect against shock loads or side loading.
Note: Opposite corner outrigger pad lift.
When lifting a rated load over a front or rear corner of the crane it is possible that frame
torsion (twist) will cause the opposite corner outrigger pad to lift off the ground a few
inches. This is normal and not an indication of a stability problem.

Emergency Procedures
Emergency Procedures
When operational aids are inoperative or malfunctioning, the following requirements shall
apply for continued use or shutdown of the crane.
1. Steps shall be taken to schedule repairs and recalibration immediately. The
operational aids shall be put back into service as soon as replacement parts, if
required, are available and the repairs and recalibration can be carried out. Every
reasonable effort must be made to expedite the repairs and recalibration.
2. When a load indicator, rated capacity indicator, or rated capacity limiter is inoperative
or malfunctioning, the designated person responsible for supervising the lifting
operations shall establish procedures for determining load weights and shall ascertain
that the weight of the load does not exceed the crane ratings at the radius where the
load is to be handled.
3. When a boom angle or radius indicator is inoperative or malfunctioning, the radius or
boom angle shall be determined by measurement.
4. When an anti-two-block device, two-blocking damage prevention, or two-block
warning device is inoperative or malfunctioning, the designated person responsible for
supervising the lifting operations shall establish procedures, such as assigning an
additional signal person, to furnish equivalent protection.
5. When a boom length indicator is inoperative or malfunctioning, the designated person
responsible for supervising the lifting operations shall establish the boom length at
which the lift will be made by actual measurement or marking on the boom.
6. When a level indicator is inoperative or malfunctioning, other means shall be used to
level the crane within the level requirements specified by the manufacturer.
In certain situations, It may be necessary to override the automatic motion limiter of the RCI/
ATB unit in order to safely operate the crane. These include, but are not limited to:
The load block may lift the ATB weight before the load line can be tensioned while stowing
the boom. This will cause a motion cutout. Overriding the system, in this situation is
acceptable in order to continue to winch in slack line, securing the boom.

Emergency Boom Retraction
The Terex BT Boom Truck is equipped with a pilot operated holding cartridge in the base of
the extension cylinder. This cartridge provides a means of supporting loads in a static
condition to prevent any inward creep. It also provides support in the event of a ruptured
line, or hydraulic failure.
These holding cartridges should be maintained in a condition to hold a rated load

suspended with the power source shut off and the handle actuated to the retract position.
Although we DO NOT recommend that you adjust this cartridge, it may be used as an
emergency retraction device in the case of ruptured lines or pump failure. This may be
accomoplished with the following procedures:
1. Have qualified operator (per ANSI B30.5) hold the extend handle in the retract position.
2. Loosen the nut on the counterbalance cartridge and rotate the screw very slowly
clockwise until inward movement is noticed. Be sure to count the turns so the
cartridge may be returned to original adjustment.
3. If the boom is not elevated sufficiently, friction may hold it in place. An external load
may need to be applied against the boom tip to retract the boom.
APPLY FORCE VERY CAREFULLY SO AS NOT TO DAMAGE ANY BOOM

COMPONENT. IF BOOM WILL NOT RETRACT, DO NOT FORCE IT OR
INTERNAL DAMAGE MAY RESULT.

Emergency Lowering of Boom

The Terex BT Boom Truck is equipped with a pilot operated holding cartridge in the base of
the topping cylinder. This cartridge provides a means of supporting loads in a static
condition to prevent any downward creep. It also provides support in the event of a
ruptured line, or hydraulic failure.
This holding cartridge should be maintained in a condition to hold a rated load suspended
with the power source shut off and the handle actuated in the down position.
Although we DO NOT recommend that you adjust this cartridge, it may be used as an
emergency lowering device in the case of ruptured lines or pump failure. This may be
accomoplished with the following procedures:
1. Have qualified operator (per ANSI B30.5) hold the topping handle in the down position.
2. Loosen the nut on the counterbalance cartridge and rotate the screw very slowly
clockwise until downward movement is noticed. Be sure to count the turns so the
cartridge may be returned to original adjustment.
3. Regulate boom down speed with the control handle.
DO NOT PUT ANY PART OF YOUR BODY BETWEEN THE TOPPING CYLINDER,
THE BOOM, OR THE TURRET. CRUSHING INJURY OR DEATH CAN OCCUR.

Emergency Rotation
The Terex BT Boom Truck is equipped with a spring applied, pressure released rotation
brake. THis brake will only allow rotation if there is sufficient hydraulic pressure. In case of
hydraulic failure this brake will have to be HYDRAULICALLY released. This may be
accomplished with the following procedures:
1. Use emergency retraction procedures to fully retract the boom.
2. Use emergency lowering procedures to lower the boom about 1 foot above the boom
rest. Attach a tag line to the boom..
3. Plumb a PORT-A-POWER or other hydraulic source into the brake port on the rotation
gearbox..
4. Remove counterbalance valve cartridges from motor..
5. Pressurize the brake port to 600 PSI and rotate boom over boom rest with a tag line.
Oil will be lost through counterbalance valve cavities as the boom is rotated. Catch
any spilled oil in a pan..
6. Release hydraulic pressure and reattach brake line. Reinstall counterbalance valves..
ONCE BOOM IS IN BOOM REST, USE STRAPS TO SECURE BOOM INTO

BOOM REST FOR ROADING. IF LOADBALL CANNOT BE SECURED TO
TIEDOWN POINT, REMOVE IT AND SECURE ANY LOOSE WINCH CABLE.

Emergency Retraction of Outriggers

The Terex BT Boom Truck is equipped with pilot operated holding cartridges in both parts
of the outrigger cylinder. The extend cartridges provide a means of supporting loads in a
static condition to prevent any upward creep of the outrigger legs. They also provide
support in the event of a ruptured line, or hydraulic failure. The retract cartridges hold the
outriggers in position during roading
These holding cartridges should be maintained in a condition to hold a rated load

suspended with the power source shut off and the handle actuated in the retractposition.
These cartridges may be used as an emergency retraction device in the case of ruptured
lines, or hydraulic pump failure. This may be accomplished with the following procedures:
1. Have qualified operator (per ANSI B30.5) hold the outrigger handle in the retract position.
2. Loosen the jam nut on the extend holding valve cartridge. Rotate the screw very
slowly clockwise using a 3/16” allen wrench until inward movement is noticed. Once
the truck tires are on the ground, further retraction will require the use of a jack or Come-
Along. After adequate ground clearance is obtained, secure the outriggers in the
retracted position with a chain or sling. Then return the holding valve cartridge to its
original setting. FInally, remove the jack or Come-Along. The chain or sling should be
left in place until the hydraulic system is restored to proper working order.
1 Jam Nut 3 Retract Cartridge

2 Extend Cartridge 4 Cylinder Retract Tube
NEVER RETRACT THE OUTRIGGERS UNTIL THE BOOM IS SECURED INTO

THE BOOM REST FOR ROADING.

Roading the Unit
Before leaving the work site or repositioning the crane at the work site, always:
1. Retract boom. Stow boom on the boom rest. Always use the boom rest.
2. Using D-Ring on rear of truck, attach load line hook and hoist in until slack is taken up.
On tractor mount models, always use boom rest for securing the boom and tie off load
line hook to attachment provided
NEVER LEAVE BOOM ELEVATED OR LOAD SUSPENDED WHEN UNIT IS

UNATTENDED.
3. Fully retract all outriggers.
IF UNIT IS EQUIPPED WITH OPTIONAL FRONT BUMPER MOUNTED

STABILIZER, IT MUST BE EXTENDED LAST TO PREVENT STRUCTURAL
DAMAGE.
4. Disengage Power Take Off (PTO).

5. Secure any load or lifting attachments (steel platforms, roofer’s package) to the flatbed.
THE TEREX CRANES BOOM TRUCK IS NOT A PICK AND CARRY CRANE.
NEVER DRIVE TRUCK WITH BOOM EXTENDED OR ELEVATED, OR WITH A
LOAD SUSPENDED FROM LOAD LINE HOOK.
NEVER LEAVE THE WORK SITE OR REPOSITION THE TRUCK CRANE

WITHOUT FIRST SECURING THE BOOM IN ROAD TRAVEL POSITION AND
FULLY RETRACTING ALL OUTRIGGERS.
You should always know the maximum road height of your crane when repositioning at the
job site or preparing for road travel. A placard like the one shown above, which shows the
height of your crane as manufactured and installed is attached to the dash board inside the
truck cab. Severe personal injury, as well as damage to the crane and truck, can result from
failure to observe overhead obstructions during repositioning at the job site or during road
travel.
ALWAYS KNOW YOUR MAXIMUM ROAD HEIGHT AND OBSERVE ALL

OVERHEAD OBSTRUCTIONS. FAILURE TO DO SO MAY RESULT IN SEVERE
DAMAGE TO THE CRANE/VEHICLE AND/OR DEATH OR SERIOUS INJURY TO
OPERATING PERSONNEL.

Disassembly
BT3870 Jib Stowage

If you have installed the optional side stow jib, the instructions for stowing the jib follow.
Jib Stowage Procedure

1. Starting with a fully levelled boomtruck, retract the boom until it is extended
only 2 ft. Rotate the boom to the street side of the boom rest, and lower until
jib head can be reached from the ground.
DO NOT RIDE OR CLIMB ON BOOM OR JIB. SERIOUS INJURY OR

DEATH COULD OCCUR. USE A LADDER OR SUITABLE PLATFORM TO
REACH ELEVATED PIN LOCATIONS.
3. Remove the ANTI-TWO BLOCK CHAIN CLEVIS from the anti-two-block switch.

Disassembly
1 Anti-Two Block Chain Clevis
4. Remove ANTI-TWO BLOCK WEIGHT from wire rope.
1 Anti-Two Block Weight
5. Remove the JIB HEAD GUIDE PIN. Extract the wire rope from the JIB HEAD
SHEAVE. Reinstall JIB HEAD GUIDE PIN.

1 Guide Pin 3 Jib Head Sheave
2 Jib Tip Anti-Two Block Receptacle 4 Anti-Two Block Switch
6. Remove JIB AN TI-TWO BLOCK PLUG from the boom head and install in open
RECEPTACLE on the jib base.
1 Jib Anti-Two Block Receptacle 3 Retaining Pin

2 Anti-Two Block Receptacle 4 Anti-Two Block Switch
7. Remove ANTI-TWO-BLOCK SWITCH, RETAINING PIN, and PLUG from the jib.
Reinstall on boom head.
8. Extract WIRE ROPE from jib cable retainer, back to the boom head.

Disassembly
1 Boom Head 2 Wire Rope
IF THE SECOND STAGE OF THE OPTIONAL 2 STAGE JIB HAS NOT BEEN
USED, SKIP TO STEP 14
9. Remove SECOND STAGE LOCK PIN and retainer.
1 Second Stage Stop Pin 2 Second Stage Lock Pin
10. Push the SECOND STAGE JIB in until the jib is fully retracted.

1 Second Stage Jib
11. Insert jib SECOND STAGE LOCK PIN into retracted position and secure with
retaining pin. Pull on second stage to ensure lock pin is securing second stage.
1 Second Stage Lock Pin
12. Stow the ANTI-TWO BLOCK JIB CABLE on the ANCHOR POINTS.

Disassembly
1 Anti-Two Block Cable 2 Anchor Point

CONTROLLED.
14. Remove the two jib PINS and RETAINERS on the side opposite the jib stow
brackets (curb side). Store these pins in the PIN STOW BRACKET provided.

1 Pin Stow Bracket 2 Pins/Retainers
15. Check to ensure that the boom is extended approximately 15 inches this will
allow the jib stow bars to clear the jib STOW BRACKETS.
1 Stow Bracket

Disassembly
16. Swing jib back along the side of the main boom with tag line.
CONTROL MOVEMENT OF THE JIB AT ALL TIMES TO PREVENT INJURY

AND/OR EQUIPMENT DAMAGE.
17. Jib should be parallel to the boom and the JIB STOW BAR and JIB STOW
BRACKETS in alignment.
NOTE: There are front and rear stow brackets to secure the boom, both must
be observed for proper alignment during this procedure. Refer to the following
images to be sure the locations and procedures for these brackets is understood.
1 Jib 2 Boom

1 Jib Stow Bar 3 Jib Lock Pin
2 Jib Stow Bracket
18. Lock the JIB LOCK PIN in the open position. this can be done by pulling on the
handle and adding a twist to lock it in the open position.
1 Jib Lock Pin - Open Position
19. Slowly retract the boom while observing that the jib properly engages the JIB
STOW BRACKETS.

Disassembly
1 Jib Stow Brackets
20. Lock the JIB LOCK PIN. This pin is spring loaded and will slide into it’s closed
position when the handle is rotated to the proper orientation. Confirm that the
pin is fully seated and that the jib is fully secured to the boom.
1 Jib Lock Pin - Locked Position
DO NOT PROCEED TO THE NEXT STEP UNTIL THE JIB IS FULLY AND
ABSOLUTELY SECURED TO ITS STOWAGE BRACKETS. IF THERE IS
ANY DOUBT ABOUT THE SECURITY OF THE JIB ON THE STOWAGE
BRACKETS, STOP AND REVIEW THE STEPS CONTAINED IN THIS
MANUAL, CONFIRMING THE SECURITY OF THE STOWED JIB BEFORE
PROCEEDING.
21. Remove the remaining two PINS and retainers from boom/jib ears.

1 Pin
22. Stow the two PINS and RETAINERS in the outer PIN STOW BRACKET.
1 Pin Stow Bracket 2 Pins/Retainers

Disassembly
1 Guide Pin Locations 2 Retainer
24. Route Cable through both sheaves and re-install the PINS and RETAINERS.
26. Winch in the excess cable while being sure that the cable is spooling on the
winch drum correctly. It may be necessary to provide tension on the wire rope
to ensure that it lays on the winch drum correctly.

Disassembly
BT28106 Jib Stowage

If you have installed the optional side stow jib, the instructions for stowing the jib follow.
Jib Stowage Procedure

1. Starting with a fully levelled boomtruck, retract the boom until it is extended
only 2 ft. Rotate the boom to the street side of the boom rest, and lower until
jib head can be reached from the ground.
DO NOT RIDE OR CLIMB ON BOOM OR JIB. SERIOUS INJURY OR

DEATH COULD OCCUR. USE A LADDER OR SUITABLE PLATFORM TO
REACH ELEVATED PIN LOCATIONS.
1 Boom 2 Jib
1 Hook Ball

3. Remove the ANTI-TWO BLOCK CHAIN CLEVIS from the anti-two-block switch.
1 Anti-Two Block Switch 3 Anti-Two Block Chain

2 Anti-Two Block Weight
4. Remove ANTI-TWO BLOCK WEIGHT from wire rope.
5. Remove the JIB HEAD GUIDE PIN. Extract the wire rope from the JIB HEAD
SHEAVE. Reinstall JIB HEAD GUIDE PIN.
6. Remove JIB ANTI-TWO BLOCK PLUG from the boom head and install in open
RECEPTACLE on the jib base.
7. Remove ANTI-TWO-BLOCK SWITCH, RETAINING PIN, and PLUG from the jib.
Reinstall on boom head.
1 Guide Pin

Disassembly
1 Retainer Pin
8. Extract WIRE ROPE from jib cable retainer, back to the boom head.
1 Wire Rope 2 Boom Head
IF THE SECOND STAGE OF THE OPTIONAL 2 STAGE JIB HAS NOT BEEN
USED, SKIP TO STEP 14.
9. Remove SECOND STAGE LOCK PIN and retainer.

1 Jib Lock Pin
10. Push the SECOND STAGE JIB in until the jib is fully retracted.
11. Insert jib SECOND STAGE LOCK PIN into retracted position and secure with
retaining pin. Pull on second stage to ensure lock pin is securing second stage.
1 Jib Lock Pin - Locked Position
12. Stow the ANTI-TWO BLOCK JIB CABLE on the ANCHOR POINTS.

Disassembly

CONTROLLED.
14. Remove the two jib PINS and RETAINERS on the side opposite the jib stow
brackets (curb side). Store these pins in the TOOL BOX.
1 Jib Lock Pin
15. Check to ensure that the boom is extended approximately 15 inches this will
allow the jib stow bars to clear the jib STOW BRACKETS.
16. Swing jib back along the side of the main boom with tag line.
CONTROL MOVEMENT OF THE JIB AT ALL TIMES TO PREVENT INJURY

AND/OR EQUIPMENT DAMAGE.

1 Pin Stow Bracket
17. Jib should be parallel to the boom and the JIB STOW BAR and JIB STOW
BRACKETS in alignment.
NOTE: There are front and rear stow brackets to secure the boom, both must
be observed for proper alignment during this procedure. Refer to the following
images to be sure the locations and procedures for these brackets is understood.
18. Lock the JIB LOCK PIN in the open position. This can be done by pulling on
the handle and adding a twist to lock it in the open position.
19. Slowly retract the boom while observing that the jib properly engages the JIB
STOW BRACKETS.

Disassembly
Jib Lock Pin Location

20. Lock the JIB LOCK PIN. This pin is spring loaded and will slide into it’s closed
position when the handle is rotated to the proper orientation. Confirm that the
pin is fully seated and that the jib is fully secured to the boom.
DO NOT PROCEED TO THE NEXT STEP UNTIL THE JIB IS FULLY AND
ABSOLUTELY SECURED TO ITS STOWAGE BRACKETS. IF THERE IS
ANY DOUBT ABOUT THE SECURITY OF THE JIB ON THE STOWAGE
BRACKETS, STOP AND REVIEW THE STEPS CONTAINED IN THIS
MANUAL, CONFIRMING THE SECURITY OF THE STOWED JIB BEFORE
PROCEEDING.

21. Remove the remaining two PINS and retainers from boom/jib ears.
22. Stow the two PINS and RETAINERS TOOL BOX.
24. Route Cable through both sheaves and re-install the PINS and RETAINERS.
1 Pin
26. Winch in the excess cable while being sure that the cable is spooling on the
winch drum correctly. It may be necessary to provide tension on the wire rope
to ensure that it lays on the winch drum correctly.

Disassembly

Maintenance
Safety Practices
1. ALWAYS apply the parking brake on the truck before undertaking any repairs to the
crane.
2. Lower all loads to the ground so load line is slack.
3. Move all controls to neutral position.
4. Disengage the PTO and turn off ENGINE
5. Attach a caution sign to the start controls warning personnel that the unit is being
serviced.
6. DO NOT stick hands or tools into any hole in boom sections while power is on or
boom sections are moving.
7. DO NOT perform maintenance, adjustment, or repair procedure unless authorized to
do so. Make sure all applicable instructions have been read and are understood
thoroughly.
8. DO NOT check for hydraulic leaks with hands. Oil under pressure can penetrate
human skin causing serious injury. Oil under pressure can be nearly invisible; Check
for hydraulic leaks with a piece of cardboard or wood.
DO NOT GO NEAR LEAKS
1. High pressure oil easily punctures skin causing serious injury, gangrene or
death.
2. If injured, seek emergency medical help. Immediate surgery is required to
remove oil.
3. Do not use finger or skin to check for leaks.
4. Lower load or relieve hydraulic pressure before loosening fitting.
9. Hydraulic oil is flammable; DO NOT check inside hydraulic tank with an open flame.

Maintenance
DO NOT SPILL OR DUMP OIL
1. Keep open flame away.

2. Injury could result if not cleaned up.
3. Oil is a regulated/hazardous waste.
4. Capture oil when repairing or draining systems.
5. Disposal must conform to state/federal regulations.
6. Do not overfill containers or reservoirs.
10. DO NOT alter specified flow and pressure settings. Higher than specified flows and
pressures can cause damage to crane and hydraulic components. Lower than
specified flows and pressures can result in loss of power.
11. DO NOT weld or have open flame close to hydraulic lines and components without
first placing a protective cover over them.
12. DO NOT remove cylinders until working parts are resting on the ground or are securely
blocked from movement.
13. Components are heavy. DO NOT attempt to lift them by hand; use a hoist, jacks, or
blocking
14. This boom truck has a step and two grab handles on either side for climbing onto and
off of the platform. Crane owner/user shall provide sturdy ladders for personnel to gain
access to components which cannot be reached from either the platform or from the
top of the flatbed. DO NOT allow personnel to climb onto turntable, winch, or the top
of the boom. Use a sturdy ladder to gain access to these locations.

General Work Practices
The following points are effective work practices that make the job go smoother and
provide for the best quality in the repair of the crane.
1. Before disconnecting wires, hoses or tubes, tag them for proper identification at
reassembly.
2. Before removing a component (pump, motor, valve, etc.), match mark its mounting
position in relation to the adjacent component
3. Before disassembling any multiple section component (pump, motor, valve, etc.), mark
the position of each section in relation with the other.
4. Before removing shims, tie them together and identify the location.

Maintenance
Storing Components
1. Store new components (valves, pumps, motors, cylinders, hoses, tubes, fittings) in a
clean, dry indoor location.
2. DO NOT unpack components or remove port plugs until the components are needed.
3. Once unpacked, carefully inspect each component for damage that may have
occurred during shipping. Remove all shipping material from the ports of the
components before installing them.
4. Fittings, hoses and tubes that are not equipped with shipping caps or plugs must be
carefully cleaned before they are used. Flush the fittings, hoses and tubes with clean
hydraulic oil then seal all openings until assembly.
DO NOT USE RAGS TO PLUG OPENINGS. USE CLEAN PLASTIC OR METAL

PLUGS AND CAPS.

Cleanliness
1. When removing a component from the crane, thoroughly clean the area around it to
prevent dirt from entering the mating component or the hydraulic system. Cover all
openings with plastic to prevent dirt and water from entering.
2. Carefully clean the area around fittings before disconnecting hoses and tubes and the
mating ports of all components to prevent dirt and water from entering.
3. Use tools that are clean and in proper working condition.
4. Clean metal parts in nonflammable safety solvent. Clean rubber parts in warm soap
and water. Lubricate all parts with clean oil at assembly, unless otherwise instructed.

Maintenance
Master Lube Chart

Maintenance Checks and Lubrication
The following are the recommended maintenance instructions for the Terex Cranes Boom
Truck. The unit is equipped with special Teflon bushings at the topping cylinder and boom
hinge pin points that do not require lubrication. The outrigger hinge points do not require
lubrication either. It is recommended that an EP (Extreme Pressure) type grease be used
where greasing is indicated. The MASTER LUBE CHART above shows the proper
lubricants to use and the frequency of lubrication.
DAILY OPERATOR CHECKS
A regular schedule of maintenance is essential to keep your unit at peak operating

efficiency. Operators responsible for the care of the unit should be familiar with the daily
and weekly maintenance schedules and what to look for. Below are the items to check to
ensure the unit is in proper and safe operating condition, and recommended intervals of care.
CHECKING THE TRUCK
Proper operation of the crane is dependent on the condition of the truck, so the following
checks should be done daily:
1. Set parking brake, start engine, put transmission in neutral and engage PTO. Allow the
hydraulic system to warm up slightly. Check for any sign of oil leaks or damaged hoses.
2. Extend all four outriggers to a firm surface, raise truck to just clear tires from ground,
and shut the engine off. Move outrigger handles to unload any oil trapped in the
hoses. This is an opportunity to ensure the outrigger holding cartridges are not leaking
under load.
3. Check the lights for proper operation.
4. Check engine fluids. Maintain oil and water levels above the add mark.
Do additional checks per truck operator’s manual.
DAILY CHECKS
Before daily operation begins, the crane should be run and checked for the following:
1. Set parking brake, start engine, put transmission in neutral and engage PTO. Allow the
hydraulic system to warm up slightly. Check for any sign of oil leaks or damaged hoses.
2. Extend all four outriggers to a firm surface, raise truck to just clear tires from ground,
and shut the engine off. Move outrigger handles to unload any oil trapped in the
hoses. This is an opportunity to ensure the outrigger holding cartridges are not leaking
under load.
3. Check all controls for any signs of sticking and proper operation of functions. With
boom elevated and extended, shut off engine, move topping and extension control
handles, and check for signs of boom drift.
4. Check to make certain that the load line is properly spooled on the winch drum and
that it is not damaged.

Maintenance
5. Check all Operator Aids for proper operation (Anti-2 Block, Load Moment Sensing
System and Holding Valves).
6. Do daily lubrication.
7. Check that the downhaul weight (load block or ball) is properly secured to the loadline
and the hook safety latch is in proper operating condition.
WEEKLY CHECKS
The following weekly checks should be performed in addition to the daily checks:
1. Check mechanical linkages for signs of wear or binding. Lubricate as necessary with
10 weight motor oil.
2. With all boom sections retracted, move boom side to side and check for missing wear
pads between boom sections and excess clearance or looseness in rotation gearbox
(more than 2”-4” of play side to side at boom tip).
3. If machine is salt covered, wash weekly to prevent rust and corrosion.
4. Do weekly lubrication.
MONTHLY OPERATIONAL CHECKS
The following checks should be performed monthly in addition to the daily and weekly checks:
1. Check oil level in the rotation gearbox. It should be filled with HD-80W90 to the fill
plug. At this time a shot of grease should be added to the grease zerk on the upper
bearing. (Caution: Do not overgrease this bearing!)
2. Check for excessive movement in the rotation gear mechanism. If over 4” of
movement (side to side) is detected by moving the boom tip back and forth when fully
retracted, it would be considered excessive. (See Care and Maintenance of the
Rotation System on page 181.)
3. Inspect all crane mounting bolts for signs of looseness or breakage. Replace or
retorque where necessary. (See Care and Maintenance of the Rotation
SystemSuggested Torque Ratings on page 0 .)
4. Extend all boom sections and check for physical defects, cracks and signs of
overstress. Check the boom while extending to make sure it is properly sequencing.
With the boom fully extended, check for excessive droop. Check the torque on the
retraction cables (torque must be at 30-35 ft/lbs). Check to make certain all boom
wear pads are in place and tight, and no excessive slop between boom sections is
detected. (If repair is indicated, see BT3870 Wear Pad Adjustment and Replacement
on page 237 or BT28106 Wear Pad Adjustment and Replacement on page 252.)
5. Check that all boom and outrigger pins are properly secured and make certain that
keepers and snap rings are present and properly installed.
6. Inspect load line for signs of kinking, crushing, cutting, or other damage.
7. Inspect weldments for signs of cracks at weld joints on all structural members.
8. Lubricate PTO with multi-purpose grease

1 Shaft Cover Screws
2 Grease Zerk
PTO Lubrication Instructions:

1. Remove Shaft cover Screws (1) and remove cover.
2. Using grease gun, apply 2-3 pumps of multipurpose grease through grease zerk
(2).
3. Replace shaft cover and tighten screws.
9. Change hydraulic oil filter.

Maintenance
90-Day Maintenance Items

The following maintenance procedures should be done every 90 days in addition to the
daily, weekly, and monthly checks:
1. Check and reset the rotation gear backlash. (See Backlash Adjustment on page 288.)
2. Torque rotation gear mounting bolts. (See Suggested Torque Ratings on page 0 .)
3. Run the unit long enough to get the hydraulic system fully warmed up and inspect
thoroughly for signs of leakage due to worn hoses or loose fittings. Correct as necessary.
4. Check the load block and the downhaul weight for signs of overloading, spread side
plates, elongated holes, bent tie bolts or cracks.
5. Any hooks on the load blocks or downhaul weights having a throat spread 15% wider,
or twisted from the normal configuration by 10° or more, should be replaced.
6. Check all placards and load charts to ensure they are legible. If any placards are
damaged or missing, they must be replaced.
7. Inspect all electrical wiring and operator aids (Anti- Two Block, Rated Capacity
Indicator System, holding valves) for proper functioning and signs of deterioration.
8. Replace hydraulic tank breather.

Semi-Annual Maintenance Items
The following checks should be done semi-annually in addition to the daily, weekly, and
monthly checks:
1. Torque the mainframe and rear outrigger mounting bolts. (See Suggested Torque
Ratings on page 0 .)
2. Check Hydraulic system pressures and adjust as necessary.
3. Inspect all visible wear pads for excessive wear or looseness.
ALL MAINTENANCE AND INSPECTION INTERVALS ARE BASED ON NORMAL

USE. EXCESSIVELY HIGH DUTY CYCLE OR DUSTY, DIRTY ENVIRONMENTS
WILL REQUIRE MORE FREQUENT MAINTENANCE INTERVALS. A UNIT THAT IS
SUBJECTED TO PARTICULARLY ROUGH TREATMENT, OR IS FREQUENTLY
OVERLOADED IS SUBJECT TO PREMATURE FAILURE.

Maintenance
Filters and Maintenance

DETERMINING THE CONDITION OF THE OIL
The only definite way to assure that all accumulated contaminants which will wear the
pump, motors, and cylinders are removed from the hydraulic system is to drain the old oil
and replace it with new. If oil did not break down or could be kept lean permanently,
changing would not be necessary. The easiest way to determine the condition of oil is to
obtain a sample from the system and make a visual examination.
Drain some oil from the reservoir into a clean glass container. If it has a burnt or rancid
smell, or is cloudy or dark in color, the oil needs to be changed. If water appears in the
bottom of the glass after it has stood awhile there may be either an opening for water to
enter into the system, or the unit has been operating under conditions causing
condensation. A good example of condensation from extreme temperature changes is
when the unit is parked in a warm garage after being out in the cold all day.
The entry and sustained presence of water, solvents, and abrasive dirt will adversely affect
the proper condition of the oil. This can cause premature breakdown of viscosity, anti-
foam, lubrication, and anti-rust characteristics of the oil. High operating temperatures and
water will cause an increase in the oil’s oxidation rate. As the oil oxidizes, sludge and
varnish forming materials will be deposited in the pumps, valves, cylinders, and lines; thus
increasing the rate of wear on the components.
If the oil shows that water is present, or if any other contaminants are suspected, the oil
should be changed. Whenever the oil is changed, a new oil filter should always be used.
Oil contamination can also be tested for contaminate size and content, this may help in
diagnosing an issue.
If the oil is drained from the unit and replaced with new oil, the unit must be run for a total
of 10 hours after the change before another sample is taken for testing. This will acclimate
the oil to the unit and give more conclusive results during testing.
FILTRATION
Adequate protection against oil contamination has been given to the system through filtration.
This system is equipped with a 10 micron spin on type filter to strain out particles down to
10 microns in size. (40 microns is as small as the eye can see).
All new equipment will experience some wear during initial operation. This should improve
the operation of the new components after they have seated. This wear will introduce small
metal particles into the system - most of which will be collected by the filter. After this
breaking in process, it is mandatory that the first filter change occur. Terex recommends
the filter on a new unit be changed after 100 hours of operation or 30 days of use,
whichever comes first. The recommended interval of change after this initial break-in is
every 90 days, or when the gauge on the filter indicates 25 PSI (RED ZONE) or above.
If the filter pressure rises above 25 PSI with the pump at 3,000 RPM it is a warning that the
filter is in the bypass mode and filtration is not occurring.

NOTE: Bypass with cold oil is normal and acceptable.
The unit should always be allowed to gradually warm up (oil temperature above 60° F)
before checking the filter bypass gauge.
The oil filter is mounted on the front of the oil tank, as shown above. To change the return
filter, shut off the power supply to the pump and unscrew the filter canister. Be careful to
catch any oil spilled in a drain pan. Slightly lubricate the rubber seal on the new filter and
tighten 1/3 turn past contact.
IMPROPER OR INADEQUATE MAINTENANCE OF THE HYDRAULIC OIL OR OIL

FILTER WILL RESULT IN PREMATURE WEAR TO VALVES, CYLINDERS,
MOTORS, ETC.
SELECTING THE OIL

When buying oil, remember there is no other single factor more important to the unit’s life
and economic operation than the quality of the oil used. Protect the oil from losing its
proper condition by rigidly following the inspection schedules and servicing of filters.
Our equipment has been quality engineered for quality oils. The finely machined cylinder
and valve components cannot be expected to withstand abuse due to improper care of the
hydraulic system. The most economical operation of the hydraulic system results from the
use of a premium quality oil and conscientious preventative maintenance in accordance
with this manual.
Terex recommends the following oil, because of its quality and availability.
RECOMMENDED OIL AMBIENT TEMPERATURE VISCOSITY INDEX AT 100° C

Arctic -55°F 217
RENOLIN AW 32 -40° to 210°F 150
Any quality hydraulic oil formulated for heavy-duty applications and meeting Texaco
performance requirements is acceptable for use in a Terex BT Boom Truck. However,
different manufacturer’s use chemical formulations which may not be compatible.
Therefore, at a minimum, you must verify that any makeup oil added is compatible with the
oil already in the system. When changing oil, if a different brand is used, the system should
be flushed by cycling all cylinders at least once to their limits to insure that as much as
possible of the old oil has been removed from the system.

Maintenance
NOTE: Observe all oil handling hazards. Used oil should be recycled or reclaimed.
Remember, oil is not a disposable resource and it is your responsibility to maintain
sound environmental practices in regards to used oil and other fluids
IMPROPER OR INADEQUATE MAINTENANCE OF THE HYDRAULIC OIL OR OIL

FILTER WILL RESULT IN PREMATURE WEAR TO VALVES, CYLINDERS,
MOTORS, ETC.

Rotation System Maintenance and Troubleshooting
Swing System
The swing system is equipped with a counterbalancing motor control. There are some
basic reasons to have this system as follows:
1. To insure that the swing brake is used only as a parking brake instead of a service
type brake. The brake system is not designed to slow the rotation of the unit as some
people believe. It is designed to hold the boom from drifting after it is brought to a
stop hydraulically. To use in any other way would cause premature wear and early
failure of the brake. One counterbalance valve must pilot open the other to allow swing
movement. This in turn provides a brake release signal so the brake is fully released
before the boom moves.
2. The counterbalance valves used on the swing system have a 4:1 operating ratio. When
used in the pilot to open mode, the sleeve portion of the cartridge may be moved in
mere thousandths of an inch which provides a very precise metering control.
OPERATE MODE
When the swing control valve is shifted to swing counterclockwise, oil is directed to the
valve port on the counterbalance valve which free-flows through to the motor inlet. But, the
motor cannot turn because the counterbalance valve on the return side of the motor is
closed and the swing brake is applied.
As pressure at the motor inlet increases, the internal shuttle valve shifts thus directing pilot
pressure to release the parking brake. At the same time, this pilot pressure opens the
counterbalance valve on the return side, allowing the motor to swing the boom. Return oil
then flows through the other counterbalance cartridge and returns to tank through the
return circuit.
The swing brake springs and the counterbalance valve are sized so that the brake releases
at lower pressure than the counterbalance valve opens. This action prevents premature
brake wear and chatter that could occur if the motor was allowed to turn through a partially
applied brake.
If the boom attempts to swing faster than the supply of oil to the motor, pressure on the
inlet side of the motor will decrease. This decrease in pressure will cause the
counterbalance valve, at the motor outlet, to partially close and restrict return oil flow, thus
decreasing the swing speed. With a given flow rate to the motor (determined by position of
swing control valve spool), the counterbalance valve will automatically establish a balance
between spring force trying to close the valve and pilot pressure trying to open the valve;
therefore, the swing speed will be controlled at a constant rate.
NEUTRAL MODE
As the swing control valve is shifted to the neutral position; pressure at the motor inlet,
counterbalance valve, and swing brake decreases. As pressure decreases, the
counterbalance valve gradually closes, bringing the boom to a smooth stop. The Swing
brake then applies, holding the swing in a “zero drift” condition. Braking is done primarily

Maintenance
by the counterbalance valve which prevents brake chatter that could occur if only the swing
brake was used to stop the swing motion. The swing brake is also delayed from engaging
by a check valve in the pressure line.This gives more assurance that the swing stops before
the brake engages, maintaining long life of the brake components.
If pressure is lost for any reason while swinging, the counterbalance valve will fully close
and the swing brake will spring apply to stop the swing motion. This is why it is important
to smoothly meter the application and release of the swing control handle. To assist the
operator with these requirements, a brake application restrictor orifice and brake release
free flow check valve allow the brake to release quickly and re-engage slowly. The
schematic on the next page will aid in following the descriptive operation of the swing system.
SWING SYSTEM FLOWCHART
1 Valve Section 5 Brake Release Free-Flow Check

2 Counterbalance Cartridges 6 Brake Application Restrictor Orifice
3 Swing Brake 7 Brake Release Line
4 Shuttle 8 Hydraulic Motor

Care and Maintenance of the Rotation System
Contact Terex Service Parts Department to receive overhaul information for the gearbox on
the unit. Have the serial number available at time of call and the information will be faxed to
you.
The following steps will produce the longest possible life of the rotation bearing and
rotation gearbox:
1. Terex recommends that the torque be checked on the rotation gear hold-down bolts
every 90 days. This inspection should be repeated more often for boom trucks that
see heavy cycle operation or overloading. The figures below show the location of the
rotation bolts.
FAILURE TO OBSERVE THE ABOVE RECOMMENDATION COULD RESULT IN

FAILURE OF ROTATION GEAR MOUNTING BOLTS AND ENDANGER THE
OPERATOR AND JOB SITE PERSONNEL.
2. Regular periodic lubrication will increase the life and serviceability of the rotation
bearing. Being a heavily loaded bearing, it’s recommended that an extreme pressure
grease (such as Texaco Starplex #2) be used.
BT3870 Mainframe/Turret Assembly - Top View
1 Turret 4 Rotation Bearing

2 Mainframe 5 Rotation Drive Gear
3 Rotation Bearing Shroud

Maintenance
BT3870 Mainframe/Turret Assembly - Side View
1 Turret 4 .875-9 GR8 Hex Head Bolt

2 Mainframe 5 Rotation Bearing
3 Turret Base Plate 6 Mainframe Top Plate

BT28106 Mainframe/Turret Assembly - Top View
1 Rotation Bearing Shroud 4 Rotation Bearing

2 Turret 5 Rotation Drive Gear
3 Mainframe

Maintenance
BT28106 Mainframe/Turret Assembly - Side View w/ Detail
1 Turret 4 Hex Head Bolt, .875-9, GR8

2 Rotation Bearing 5 Turret Base Plate
3 Mainframe

Rotation Bearing Lubrication
1 Rotation Bearing 4 Grease Line

2 Turret 5 Main Frame
3 Grease Fitting
Under normal operation, the rotation bearing should be greased once a week. The grease
fittings are located on either side of the mainframe, near the upper outrigger gussets. There
is one grease fitting for each side of the rotation bearing, 180° apart.
To properly grease this bearing, the unit should be set up with the outriggers in an
operating position. Attach the grease gun to a fitting and apply 3 full shots from the grease
gun. Repeat for the other grease fitting. Then rotate the boom 90° and repeat the above
steps. This operation should continue through a 360° cycle of the rotation. See the previous
location chart.
NOTE: A shot is considered as one full pump stroke on a standard chassis type
grease gun. It is important to not over-grease and create a wasteful run-off situation.

Maintenance
Rotation Gearbox and Gear Teeth

1. The teeth of the rotation gear as well as the rotation gearbox pinion should be
lubricated regularly with a good open coat lubricant (Texaco Texclad #2 or spray
equivalent). The grease is purged from these teeth by the very nature of the
application so close attention will produce longer tooth life. Terex recommends these
teeth be lubricated once a week or more often in case of extremely heavy duty or dirty
cycling applications.
2. The rotation gearbox used on the unit is a double planetary type. The gearbox is filled
to the fill plug on the upper housing of the gearbox. The oil used in this gearbox
should be an extreme pressure lubricant, refer to the swing drive manual provided in
your boom truck manual pack. It is advisable to check this fluid level about once a
month, unless leakage around the gearbox is noted.
The gearbox is equipped with a grease zerk on the upper pinion bearing. Give this zerk a
shot of grease about once a month to insure this bearing has adequate lubrication (see
following illustration).
NOTE: A shot is considered as one full pump stroke on a standard chassis type
grease gun. It is important to not over-grease and create a wasteful run-off situation.
DO NOT OVER-LUBRICATE THIS BEARING OR THE GREASE WILL BE

PUMPED OUT OF THE UPPER PINION SEAL.
1 Output Pinion 4 Oil Check Plug

2 Breather Fill Plug 5 Counterbalances Valve
3 Grease Zerk

Winch Lubrication
RECOMMENDED PLANETARY GEAR OIL
Field experience, supported by engineering endurance tests, indicates the use of the
proper gear oil and a program of regular preventative maintenance will help provide
extended gear train life and reliable hoist brake performance. The information below is
intended to assist in determining which lubricant is best suited to your application.
Please refer to the winch manufacturer’s documentation (included with your manual pack)
for specific recommendations and specifications of the proper oil to use in your winch.
FAILURE TO USE THE PROPER TYPE AND

VISCOSITY OF PLANETARY GEAR
OIL MAY CONTRIBUTE TO
INTERMITTENT BRAKE CLUTCH
SLIPPAGE WHICH COULD RESULT IN
PROPERTY DAMAGE, SEVERE
PERSONAL INJURY OR DEATH.
SOME GEAR LUBRICANTS CONTAIN LARGE AMOUNTS OF EP (EXTREME PRESSURE)

AND ANTI-FRICTION ADDITIVES WHICH MAY CONTRIBUTE TO BRAKE CLUTCH
SLIPPAGE OR DAMAGE TO BRAKE FRICTION DISCS OR SEALS. OIL VISCOSITY WITH
REGARD TO AMBIENT TEMPERATURE IS ALSO CRITICAL TO RELIABLE BRAKE
CLUTCH OPERATION. TESTS INDICATE THAT EXCESSIVELY HEAVY OR THICK GEAR
OIL MAY CONTRIBUTE TO INTERMITTENT BRAKE CLUTCH SLIPPAGE. MAKE CERTAIN
THAT THE GEAR OIL VISCOSITY USED IN YOUR HOIST IS CORRECT FOR YOUR
PREVAILING AMBIENT TEMPERATURE.
Unless otherwise specified, it is recommended that the gear oil be changed after the first
(100) hours or two (2) months of machine operation, then every one thousand (1,000) hours
or six (6) months, whichever occurs first. The gear oil should also be changed whenever the
ambient temperature changes significantly and an oil from a different temperature range
would be more appropriate.
A warm-up procedure is recommended at each startup and is essential at ambient

temperatures below +40°F (4°C).
The prime mover should be run at its lowest recommended RPM with the hydraulic hoist
control valve in neutral allowing sufficient time to warm up the system. The hoist should
then be operated at low speeds. Raise and lower, several times to prime all lines with warm
hydraulic oil and to circulate gear lubricant through the planetary gear sets.
Failure to properly warm up the hoist, particularly under low ambient temperature
conditions, may result in temporary brake slippage due to high back pressures
attempting to release the brake, which could result in property damage, severe
personal injury or death.

Maintenance
Wire Rope Lubrication

New wire rope is lubricated during manufacturing, but this lubrication is only adequate for
initial storage and the early stage of operation. To prevent the damaging effects of
corrosion and to reduce wear, the wire rope must be lubricated at regular intervals.
The lubrication interval and the type of lubricant to be used depend on the type of wire
rope, the severity of duty, and the type of corrosive elements the wire rope is subjected to.
General guidelines are printed in your maintenance manual. Contact the nearest wire rope
dealer for specific lubrication recommendations.
The wire rope must be properly protected at all times; therefore, the gaps between the
strands and wires must be filled with lubricant to provide a complete seal. Refer to
maintenance manual for proper lubrication methods.

Storage
Storage
Machines being placed in storage must be adequately protected from deterioration during
the period of idleness. This will ensure that they can be restored to active service with a
minimum effort.
Before removing this hydraulic crane from service for extended periods, it should be
prepared for storage as prescribed in the following paragraphs. In general, three (3) major
components must undergo preparation. These are the Machine Proper, the Engine and the
Transmission. The specific procedure to be followed depends upon the expected period of
storage.
SHORT TERM STORAGE - 30 DAYS OR LESS

Short term storage requires minimal preparation.
The MACHINE should be thoroughly cleaned, lubricated in accordance with Section 4, and
painted surfaces retouched where the paint has deteriorated. exposed portions of all
hydraulic cylinders should be coated with multipurpose grease. Coat unpainted metal
surfaces with multipurpose grease after removing any rust accumulations.
The ENGINE should be prepared as prescribed in the topic “Engine Storage” on page 191.
The TRANSMISSION should be prepared as prescribed in the topic “Transmission Storage”

on page 194.
LONG TERM STORAGE - 30 DAYS OR MORE

Long term storage requires greater preparation than short term storage and must be
undertaken with greater care.
The MACHINE should be prepared as follows:

1. Perform the short term machine storage preparation, making certain that all points
with grease fittings are liberally lubricated.
2. Drain and refill the swing reducer, winch(es), axle differentials, planetary hubs and the
hydraulic reservoir. Refer to page Group 4 when servicing the reservoir.
3. Distribute the new hydraulic fluid to all parts of the system by operating all functions.
4. Clean and tape the battery cables after removing and storing the battery.
5. Coat the external ring gear of the swing bearing with open gear lubricant.
6. Block wheels so any rubber tires are not in contact with concrete. Cover tires if
exposed to sunlight.
7. Fill the hydraulic reservoir to the top AFTER THE MACHINE IS PARKED IN ITS
STORAGE SPOT.
8. Coat wire rope with lubricant.

Maintenance
9. Coat exposed cylinder rods with grease.
The ENGINE should be prepared as prescribed in the topic “Engine Storage” on page 191.
The TRANSMISSION should be prepared as prescribed in the topic “Transmission Storage”

on page 194.

Engine Storage
PREPARING ENGINE FOR STORAGE
When an engine is to be stored or removed from operation for a period of time, special
precautions should be taken to protect the interior and exterior of the engine, transmission,
and other parts from rust accumulation and corrosion. The parts requiring attention and the
recommended preparations are given below.
It will be necessary to remove all rust or corrosion completely from any exposed part before
applying a rust preventive compound. Therefore, it is recommended that the engine be
processed for storage as soon as possible after removal from operation.
The engine should be stored in a building which is dry and can be heated during the winter
months. Moisture absorbing chemicals are available commercially for use when excessive
dampness prevails in the storage area.
TEMPORARY STORAGE (30 DAYS OR LESS)

To protect an engine for a temporary period of time proceed as follows:
1. Drain the engine crankcase.
2. Fill the crankcase to the proper level with the recommended viscosity and grade of oil.
3. Fill the fuel tank with the recommended grade of fuel oil. Operate the engine for two
minutes at 1200 rpm and no load.
NOTE: Do not drain the fuel system or the crankcase after this run.
4. Check the air cleaner and service it, if necessary as outlined under Air System.
5. If freezing weather is expected during the storage period, add a high boiling point type
antifreeze solution in accordance with the manufacturer’s recommendations. Drain the
raw water system and leave the drain cocks open.
6. Clean the entire exterior of the engine (except the electrical system) with fuel oil and
dry it with air.
7. Seal all of the engine openings. The material used for this purpose must be
waterproof, vapor proof and possess sufficient physical strength to resist puncture
and damage from the expansion of entrapped air.
An engine prepared in this manner can be returned to service in a short time by removing
the seals at the engine openings, checking the engine coolant, fuel oil, lubricating oil,
transmission, and priming the raw water pump, if used.
EXTENDED STORAGE (30 DAYS OR MORE)

When an engine is to be removed from operation for an extended period of time, prepare it
as follows:
1. Drain and thoroughly flush the cooling system with clean, soft water.
2. Refill the cooling system with clean, soft water.

Maintenance
3. Add a rust inhibitor to the cooling system (refer to Group 4, “Corrosion Inhibitor”).
4. Remove, check and recondition the injectors, if necessary, to make sure they will be
ready to operate when the engine is restored to service.
5. Reinstall the injectors in the engine, time them, and adjust the valve clearance.
6. Circulate the coolant through the entire system by operating the engine until normal
operating temperature is reached (160° F. to 185° F).
7. Stop the engine.
8. Remove the drain plug and completely drain the engine crankcase. Reinstall and
tighten the drain plug. Install new lubricating oil filter elements and gaskets.
9. Fill the crankcase to the proper level with a 30- weight preservative lubricating oil MIL-
L-21260, Grade 2 (P10), or equivalent.
10. Drain the engine fuel tank.
11. Refill the fuel tank with enough rust preventive fuel oil such as Americal Oil Diesel Run-
In Fuel (LH 4089), Mobil 4Y17, or equivalent, to enable the engine to operate 10 minutes.
12. Drain the fuel filter and strainer. Remove the retaining bolts, shells and elements.
Discard the used elements and gaskets. Wash the shells in clean fuel oil and insert
new elements. Fill the cavity between the element and shell about two-thirds full of the
same rust preventive compound as used in the fuel tank and reinstall the shell.
13. Operate the engine for 5 minutes to circulate the rust preventive throughout the engine.
14. Refer to page Group 4 and service the air cleaner.
15. With an all-purpose grease such as Shell Alvania No. 2, or equivalent, lubricate the
clutch throwout bearing, clutch pilot bearing, drive shaft main bearing, clutch release
shaft, and the outboard bearings (if so equipped).
16. Remove the inspection hole cover on the clutch housing and lubricate the clutch
release lever and link pins with a hand oiler. Avoid getting oil on the clutch facing.
17. Apply a non-friction rust preventive compound, to all exposed parts. If it is convenient,
apply the rust preventive compound to the engine flywheel. If not, disengage the
clutch mechanism to prevent the clutch disc from sticking to the flywheel.
Do not apply oil, grease or any wax base compound to the flywheel. The cast iron
will absorb these substances which can “sweat” out during operation and cause
the clutch to slip.
18. Drain the engine cooling system (tag cap).

19. The oil may be drained from the engine crankcase if so desired. If the oil is drained,
reinstall and tighten the drain plug (tag cap).
20. Remove and clean the battery and battery cables with a baking soda solution and
rinse them with fresh water. Store the battery in a cool (never below 32°F.) dry place.
Keep the battery fully charged .
21. Insert heavy paper strips between the pulleys and belts to prevent sticking.

22. Seal all of the openings in the engine, including the exhaust outlet, with moisture
resistant tape. Use cardboard, plywood or metal covers where practical.
23. Clean and dry the exterior painted surfaces of the engine. Spray the surfaces with a
suitable liquid automobile body wax, a synthetic resin varnish or a rust preventive
compound.
24. Cover the engine with a good weather-resistant tarpaulin or other cover if it must be
stored outdoors. A clear plastic cover is recommended for indoor storage.
The stored engine should be inspected periodically. If there are any indications of rust or
corrosion, corrective steps must be taken to prevent damage to the engine parts. Perform a
complete inspection at the end of one year and apply additional treatment as required.

Maintenance
Transmission storage
PRESERVATIVE SELECTION
It is recommended that the highest viscosity monograde lubricant available be used for the
anticipated ambient temperature. Typically this will be a Cat TO-4 qualified lubricant. When
large swings in ambient temperature are probable J20 C, D multigrades are recommended.
Multigrade lubricants should be applied at the lower viscosity rating for the prevailing
ambient temperature i.e. a 10W20 should be used where a 10W monograde is used. If a
C-4 multigrade is used in place of J20 lubricant it is recommended that the viscosity be no
more than 10 points, i.e. 10W20.
STORAGE
If the transmission is to be stored in excess of 60 days before being put into service, the
units should be completely filled with the lubricant specified above and stored in a dry area.
It is also recommended that at least every 30 days all flanges be rotated by not less than
two complete turns to insure complete lubrication of the seals.

Chrome Cylinder Rod Storage
Hard chrome plating is primarily applied to steel cylinder rods for its wear resistant
properties, although it does provide considerable corrosion resistance as well. Once the
chrome-plated rod is assembled into a cylinder and put into service, the hydraulic fluid on
the surface of the rod provides all the corrosion resistance required for the rod during its
life cycle. As a cylinder cycles, hydraulic fluid is driven into any surface cracks that exist in
the chrome plate. When these cracks are filled with hydraulic fluid, moisture or corrosive
fluids can not penetrate the cracks. However, some machining and cleaning operations can
negatively impact the future corrosion resistance of chrome-plated shafting. For example,
additives such as chlorine, sulfur, and sodium found in Extreme Pressure (EP) coolants and
some washing solutions are known rust accelerates and can strip chrome plating from the
base metal. Cleaning processes, such as phosphate washing are also known to be
detrimental to the corrosion resistance of hard chrome plated shafting.
If the rod is not periodically cycled and is subject to a corrosive environment, moisture and
oxygen can work its way down through the chrome layer and begin to corrode the base
metal. Brand new equipment may be stored outside for a considerable period of time at the
equipment dealership before it is sold. During these times, a protective barrier must be
applied to the exposed cylinder rod. This protective barrier will preserve the integrity of the
chrome plating by preventing the elements of corrosion from getting to the metal substrate.
Cylinders should be stored in the retracted position, if at all possible. The steps outline
below cover the procedures to be followed for Protecting New Equipment from corrosion if
it must be stored in the extended position:
1. Position the equipment as it will be stored and identify all the exposed portions of the
chrome plated cylinder rods.
2. Clean any dirt and dust from the exposed portions of the cylinder rods using a dry
cloth or a cloth which has been dampened with an appropriate solvent. Do not use
caustics or acids.
3. Apply a thin coating of 1“Ferro-Kote 5856-BF” to the exposed surfaces of the chrome
plated cylinder rods. The Ferro-Kote may be thinned using a 40% Kerosene or No. 1
fuel oil mixture.
4. Inspect the cylinder rod surfaces and reapply at three to six month intervals.
5. If the equipment is to be moved and then stored again for an extended period of time
or if the cylinder is cycled, steps 1 through 4 should be repeated for all cylinder rods
that were exposed.
For the protection of Older Equipment that is to be stored, the procedure outlined above
can be used, but greater attention to cleaning the exposed portions of each cylinder rod is
required. Solvent applied with plastic or copper wool can be used, but abrasives such as
sandpaper should never be used to clean the exposed surfaces of the cylinder rod. If
surface damage to the chrome plate is discovered, the frequency of corrosion barrier
applications should be increased.
1 Ferro-Kote 5856-BF is a product of Quaker Chemical Company, Conshohocken, PA 19428

Maintenance
NOTE: Caution must be used when cleaning equipment in service with high
pressure washes. Soaps or chemicals containing chlorines or other corrosive
elements should be avoided. Cylinders should be cleaned in a retracted position as
not to expose rods to the chemicals. Cylinders should be cycled immediately
following the wash. If rods are to be stored in the extended position, refer to steps
1-4 above.

Restoration to Service
Refer to “Restoring Engine to Service” on page 198, and “Restoring Transmission to
Service” on page 199, for the procedures required to restore these components to service.
Remove the MACHINE from storage via the following procedure:

1. Remove preservative lubricants from all surfaces.
2. Check all fluid levels, adding or draining as required.
3. Lubricate the machine according to Group 4, making certain that all points with grease
fittings are lubricated.
4. Make a thorough visual inspection of the entire machine, placing special emphasis on
the condition of all hydraulic hoses.

Maintenance
Restoring Engine to Service

1. Remove the valve rocker cover(s) and pour at least one-half gallon of oil, of the same
grade as used in the crankcase, over the rocker arms and push rods.
2. Reinstall the valve rocker cover(s).
3. Remove the covers and tape from all of the openings of the engine, fuel tank, and
electrical equipment. Do not overlook the exhaust outlet.
4. Wash the exterior of the engine with fuel oil to remove the rust preventive.
5. Remove the rust preventive from the flywheel.
6. Remove the paper strips from between the pulleys and the belts.
7. Check the crankcase oil level. Fill the crankcase to the proper level with the heavy-
duty lubricating oil recommended under Lubricating Oil Specifications.
8. Fill the fuel tank with the fuel specified under Diesel Fuel Oil Specifications.
9. Close all of the drain cocks and fill the engine cooling system with clean soft water
and a rust inhibitor. If the engine is to be exposed to freezing temperatures, add a high
boiling point type antifreeze solution to the cooling system (the antifreeze contains a
rust inhibitor).
10. Install and connect the battery.
11. Service the air cleaner as outlined under Air System.
12. Prepare the generator for starting.
13. Remove the inspection hole cover and inspect the clutch release lever and link pins
and the bearing ends of the clutch release shaft. Apply engine oil sparingly, if
necessary to these areas.
14. After all of the preparations have been completed, start the engine. The small amount
of rust preventive compound which remains in the fuel system will cause a smoky
exhaust for a few minutes.
NOTE: Before subjecting the engine to a load or high speed, it is advisable to

check the engine tune-up.

Restoring Transmission to Service
1. Drain oil.
2. Install a new oil filter element(s).
3. Refill transmission with hydraulic transmission fluid to proper level.

Specifications
Pumps and Function Speeds

The pumps used on the Terex BT Series Boom Truck are fixed/positive displacement of the
rotary vane type. To produce the proper amount of flow to run the functions at full speed,
the pump shaft must be turning at 2,300 RPM.
The required speed for the pump is very important when testing the unit speeds and
checking or handling maximum loads. Remember also that pump speed and engine speed
are not always the same. For instance, if the truck transmission is equipped with a 115%
PTO, the required engine speed to achieve the desired pump RPM would be approximately
2,000 RPM. It is very important that you know what the ratio of the PTO is on the unit being
serviced.
When involved in troubleshooting a unit that is believed to have slow functions, it is

important to know the pump is receiving the proper RPM and how much flow to expect
from the pump. The following charts will allow you to accurately test the flow of the pump,
as well as determine what is the proper speed of the functions on the unit. Oil temperature
below 140º F may result in slower functions.
SYSTEM FLOWS - BT28106
GPM @ 2,300 RPM FUNCTION

38 GPM WINCH
20 GPM BOOM
9 GPM SWING
SYSTEM FLOWS - BT3870
GPM @ 2,000 RPM FUNCTION

33 GPM WINCH
18 GPM BOOM
8 GPM SWING
FUNCTION SPEEDS
The following chart is a list of the speeds you can expect from the BT Boom Truck. All
speeds are noted as being one (1) complete cycle. For instance, the swing time is for one
370° rotation, (stop to stop) at the full 2,300 RPM - and all times are in seconds.
MODEL BT3870 BT28106

SWING 70 Sec 65 Sec
EXTEND 56 Sec 110 Sec
RETRACT 40 Sec 70 Sec
BOOM UP 25 Sec 50 Sec
BOOM DOWN 17 Sec 20 Sec

Specifications
WINCH (Normal Speed) 115 FPM 135 FPM

WINCH (Combined Flow Hi 190 FPM 220 FPM
Speed)
WINCH (Motor Shift Lo 98 FPM 110 FPM
Speed)
WINCH (Motor Shift Hi Speed) 197 FPM 205 FPM
NOTE: Winch speeds based on 3rd wrap on the winch drum, and represented in
FPM of wire rope at pump speeds of:
BT3870 at 2000 pump RPM
BT28106 at 2300 pump RPM

Troubleshooting
Winch System Maintenance and Troubleshooting

Winch Maintenance and Repair
The Terex BT boom truck is equipped with a power drum type winch. It is equipped with a
spring-applied, pressure-released brake. Operation of this system requires a
counterbalance valve to insure that the brake is totally released when winching down, with
or without a load. When winching in the up direction, the input shaft turns through a sprag
clutch in the freewheel direction, which does not require the brake to be released.
Winching up the load is quite simple. To winch in, we simply supply the winch motor with
enough pressure to lift the load. When pressure is removed, the sprag clutch engages the
brake automatically to prevent the load from dropping.
Winching down is a little more complicated. There are two systems that prevent the winch
from back driving and allowing a load to drop.
1. The winch brake is a spring applied, pressure released brake that requires internal
pressure to release. The sprag clutch connects the brake to the winch drum. Being a
special one way clutch, it allows the winch to free-wheel in the up direction, and lock
in the winch down direction.
2. Counterbalance valve is a special valve blocking the flow of oil at the motor. To winch
down, the motor is pressurized and through a pilot signal passage it releases the
brake and opens the counterbalance which allows oil to flow through the motor. It
takes more pressure to open the counterbalance than to release the brake, so the
brake is totally released before the winch rotates.
NOTE: Incorporated into the counterbalance is an in-line check which allows the
motor case to drain while preventing winch pressure from entering the motor case.
To test the counterbalance valve, tee a gauge to the brake release line at the winch. The
winch should begin to move down at no lower pressure than 300- 400 PSI.
If the counterbalance system is working properly, the winch will make no attempt to turn
until this 300-400 PSI is reached. Contact Terex Service Department to receive overhaul
information for the winch on the unit. Have the serial number available at time of call and
the information will be faxed to you.

Troubleshooting
1 Hydraulic Tank 6 Winch Brake

2 Valve Section 7 Case Drain
3 Return Filter 8 Winch Motor
4 Counterbalance Valve 9 Winch Down Line
5 Winch Up Line

Two-Speed Winch Function
The Terex BT boom truck is equipped with a combined flow two-speed winch system as
standard equipment. This is controlled by a switch activated when the winch lever is at full
throw. When the winch control handle is pushed to the full throw position, oil flow from the
boom pump that is not used by the boom functions is directed to be added to winch pump
oil flow, causing an increase in the winch speed. This increase in speed can be as much as
50%. When the winch control handle is moved back from the full stroke position, the flow
of the unused boom oil is directed back to tank.
1 Unloader Tank Line 7 Control Valve Inlet

2 Winch Unloader Valve 8 Anti-Void
3 ATB Unloader Valve 9 Winch Control Valve
4 Regenerative Oil to Winch 10 Return Manifold
5 One-Way Check 11 Control Valve Return Lines
6 Regenerative Pilot Line
NOTE: The boom functions have first chance at the boom oil flow, so the winch
speed increase will be reduced when a boom function is in use.
Note in the picture above that the winch and boom control valves are linked together by a
tube at the inlets. In this tube, there is a one way check valve to insure the winch oil is not
allowed to make its way into the boom circuit. The arrow on the check valve should be
pointing away from the boom control valve.
The boom circuit oil is directed or bypassed by a ported anti-void cartridge in the inlet
section. If the pilot signal is contained in the anti-void, the winch speed will stay low. If the
pilot signal is allowed to escape through the unloader valve, it creates a pressure drop in
the spring chamber, which allows the anti-void to open. When this happens, boom circuit
oil is allowed to go to the inlet of the winch valve, where it is added to the oil from the
winch section of the hydraulic pump. If the high speed circuit fails to operate, check the
following:

Troubleshooting
1. Check all electrical connections to make sure power is getting to the winch unloader
valve solenoid.
2. Check the setting of the micro switch used to activate the 2 speed winch. Make sure
that at full throw, the switch is being triggered.
3. If the solenoid coil is getting power, check with a screwdriver on the end of the
solenoid to see if it is energized. (The metal screwdriver should be magnetically
attracted to the end of the solenoid shaft if the coil is working properly.)
4. If the coil is working, the solenoid may be stuck and should be cleaned or replaced.
5. If the high speed fails to function after replacing the solenoid, the anti-void valve is
tuck and will need to be disassembled and cleaned.
If, on the other hand, the high speed circuit is on constantly, check the following:
1. Check that the unloader solenoid coil is deenergized (off).
2. Check that the solenoid is not stuck open. Remove the tank line and plug both the
hose and valve. If normal operation is restored, the solenoid is stuck open.
3. The anti-void valve is bypassing internally.
4. Check that the 2 speed micro switch has not been damaged, and that the switch
disengages when the winch lever is at less than full throw.
COMBINED-FLOW 2 SPEED WINCH MICROSWITCH ADJUSTMENT

The combined-flow 2 speed winch is operated by a micro switch located under the winch
gearbox cover and attached to a spring plate mounted on the top of the console. This
micro switch is in a normally closed configuration, and is held in the open state until the
winch lever is activated to it’s full throw position. The 2 speed winch solenoid is not
powered until the switch is activated and changes to it closed state.
To adjust the activation point of the 2 speed switch see the following procedure.
1. Turn on the electric power of the BT with the engine NOT running. The 2 speed valve
solenoid coil should show NO magnetic pull when a screwdriver is placed near the
end of the solenoid coil.
2. Turn the adjustment set screw in until the switch goes to its normally closed state. The
2 speed valve solenoid coil should now show a magnetic pull when a screwdriver is
placed near the end of the coil.
3. Turn the adjustment set screw out until the switch button contacts the metal plate and
goes to its open state, the valve solenoid coil should now show no magnetic pull when
a screwdriver is placed near it.
4. Turn the adjusting set screw out an additional 1/8 turn.
This adjustment should show that the 2 speed is engaged only at the full throw position in
both the winch up and winch down positions. If this is not so, the following procedure will
allow you to set the activation points in both winch up and winch down.
By visually inspecting the activation mechanism during cycling of the winch control lever,
one can determine if either or both links of the activating mechanism need adjustment. A

screwdriver held near the 2 speed winch valve solenoid coil will help determine the precise
activation point of the micro switch.
1. To adjust the appropriate link, use a 3/8” open end wrench to loosen the jam nut
locking the clevis to the adjustment rod.
2. Change the length of the adjustment screw, by screwing it further into the clevis for a
later activation, and out of the clevis for a earlier activation. There is a flat blade
screwdriver slot in the end of the adjustment rod to assist in this adjustment.
Activation of the switch should occur just as the winch lever reaches its maximum
throw. The Adjustment screw can be turned out an additional 1/8 turn to assure
operation with wear over time.
3. Once the correct activation point has been set, use your 3/8” wrench on the jam nut to
lock the rod and clevis in position.

Service / Parts
General Work Practices

The following points are effective work practices that make the job go smoother and
provide for the best quality in the repair of the crane.
1. Before disconnecting wires, hoses or tubes, tag them for proper identification at
reassembly.
2. Before removing a component (pump, motor, valve, etc.), match mark its mounting
position in relation to the adjacent component
3. Before disassembling any multiple section component (pump, motor, valve, etc.), mark
the position of each section in relation with the other.
4. Before removing shims, tie them together and identify the location.

Service / Parts
Hydraulic System Description

The hydraulic system on the BT boom truck is an open center system. The open-center
means that any time the hydraulic pump is running and the control valves are in the neutral
position, oil is going into the inlet of the control valves and through the open center of the
valve and back to the tank. The oil is at low pressure because an opening to the tank exists
in the return line. If a spool is moved and the oil is diverted to an enclosed function line, the
pressure of the pump will rise to meet the load requirement. As long as the control valve
handle is held open and the load is unchanged (constant) , this working pressure will be
sustained. The pump is a fixed displacement pump; it produces a given volume each
revolution. If there was no system relief when the cylinder or actuator bottoms out, the
pump would produce enough pressure to either destroy itself, the main pressure line, or
another component. For this reason, there are system reliefs incorporated. The proper
working order and settings of these reliefs is extremely important. Operation of open center
hydraulics is illustrated on this page.

A Open Center Hydraulics/ B Open Center Hydraulics/Operate
Neutral
A1 Filter B1 Filter
A2 Open Center Valve B2 Open Center Valve
A3 Tank B3 Load
A4 Pump B4 Tank
B5 Pump
B6 Actuator
The Terex Boom Truck has an electro-hydraulic control circuit for the outriggers. The oil
flow of the boom pump is routed through the outrigger valve giving the outriggers first
chance at the oil flow. When the outrigger functions are not being activated, the oil is
bypassed to the boom control valve with a minimum of pressure loss.
The outrigger valve housing has a diagnostic test port to measure the outrigger pressure
setting. This pressure setting is adjustable via the relief valve located on the valve housing.
The outrigger valve circuit has one solenoid valve controlling bypass flow and four solenoid
valves which cause the valve to be in: neutral, extend, or retract modes. In the neutral, the
work ports are drained to tank. The valve also has five other solenoids to control each of
the 4 outriggers and the front bumper stabilizer.
The Terex boom truck has increased pressure for the boom hoist and telescope functions
compared to previous models. However the long extend cylinder would be subject to
damage if this higher pressure was used while extending the cylinder. Therefore, a relief
valve is added to this function by a tee fitting at the work port of the control valve. This
valve is adjustable to ensure proper operation.
When adjusting, the pressure reading at the boom valve must be as shown in the table
listing pressure settings.

Service / Parts
Repairs-Adjustments-Remarks Log
ITEM REQUIREMENT DATE

Service / Parts
Control Valves and Pressures

The relief pressure settings in any hydraulic system are very important. They protect the
system components from being overpressured by allowing oil above the main relief setting
to be vented to the tank. If this does not happen on a fixed displacement system, it could
cause serious damage to hoses, pumps, and other components in the system.
The chart below summarizes the valves used by function and configuration. It also gives
the rated operating pressures. All pressures are +/- 50 psi.
VALVE SPECIFICATIONS AND PRESSURE SETTINGS
FUNCTION CONFIGURATION PRESSURE

WINCH OPEN CENTER/OPEN PORT 3200 PSI OF 3000 PSI INS
(MOTOR)
BOOM OPEN CENTER/CLOSED 3500 PSI
PORT
SWING OPEN CENTER/OPEN PORT 1800 PSI
(MOTOR)
BOOM / OUTRIGGER OPEN CENTER/POWER 2900 PSI
BEYOND
TELESCOPE IN LINE RELIEF 3000 PSI
The system pressures can be checked by installing a pressure reading device on the
hydraulic test pressure ports located at the right-side console, or on the outrigger valve.
The relief used on the control valve is a pilot operated type. Oil enters through the orifice in
the end of the piston and is trapped against the seat of the pilot poppet. As long as the
relief valve has the signal trapped and isolated from the tank, the main relief will remained
closed. However, if the spring force holding the pilot poppet closed is overcome, oil can
get out faster than it can get in through the orifice in the piston poppet. This causes a
pressure drop inside the cartridge and the relief piston opens, unloading the oil to the tank.
Any malfunction of this relief is usually caused by dirt or foreign material caught on the
sealing surfaces.
The pressure relief for the outrigger valve is controlled by a pilot relief working with the
bypass spool.

Hydraulic System Pilot Relief
1 Oil Inlet Orifice 4 Piston Poppet

2 Relief Piston 5 Pilot Poppet
3 Acorn Nut 6 Adjustment Screw
The reliefs are factory set and should not be tampered with unless poor performance is
experienced. Any relief which has been removed for inspection, cleaning, or replacement
must be adjusted after installation. The figure above is a cutaway view of a typical relief
found in a BT3870.
INSPECTION AND REPAIR
Clean all parts with solvent and dry with compressed air. Make sure the orifice in the piston
is open. Examine seat on the pilot poppet and make sure it is free of grooves or ridges. If
these conditions are present, the entire relief cartridge must be replaced. All seating
surfaces should be smooth and free of nicks, scratches, or grooves. Examine o-rings and
back-up rings for any signs of damage. Replace damaged or faulty parts. All moving parts
should slide freely with only seal friction present. If possible, remove minor nicks or
scratches in poppets or poppet seats by lapping with a fine grade of lapping compound.
Clean poppets thoroughly after this procedure. If operating difficulties indicate that pilot
poppet is leaking or sticking, remove internal parts of pilot section and follow same
procedure as above. After inspecting and cleaning, immerse all parts in hydraulic oil and
reassemble. Torque pilot section in housing to 40 ft.lbs. and recheck system pressure.
HYDRAULIC SYSTEM ADJUSTMENTS
PROBLEM CAUSE REMEDY

NO PRESSURE POPPET STUCK CHECK FOR WEAR
DIRT IN POPPET CLEAN AS REQUIRED

PRESSURE ERRATIC POPPET SEAT DAMAGE REPLACE DAMAGED PARTS
POPPET STICKING CLEAN CARTRIDGE

PRESSURE SETTING NOT INTERNAL WEAR CLEAN OR REPLACE
CORRECT
ADJUSTER LOOSE ADJUST RELIEF
LEAKS DAMAGED O-RINGS OR REPLACE WORN PARTS OR
WORN PARTS RESEAL

Service / Parts
CONTROL CONSOLE HYDRAULICS - Inside Mainframe View
1 BOOM ADJUST 4 BOOM TEST PRESSURE

2 SWING ADJUST 5 SWING TEST PRESSURE
3 WINCH ADJUST 6 WINCH TEST PRESSURE
PROCEDURE FOR ADJUSTING BOOM RELIEFS
The system reliefs should be set only when the oil in the hydraulic system is warm or at
operating temperature.
1. With the control levers in neutral position, raise pump RPM to 2,300.
2. Slowly retract the boom telescope cylinder until it reaches the end of the stroke and
forces the system pressure upward to relief pressure.
NOTE: Leave all other control levers in the neutral position.

3. Check the reading on the test gauge. See pressure table for proper settings.
NOTE: Move the lever to the neutral position immediately after taking the
pressure reading to avoid excessive heat.
4. Make proper adjustments to relief by turning the relief adjustment clockwise for more
pressure and counter clockwise for less pressure. Be sure to retighten the jam nut to
10 ft.lbs. and install the acorn nut.

PROCEDURE FOR ADJUSTING SWING RELIEFS
1 SWING TEST PRESSURE PORT 2 SWING ADJUST

1. Stop the engine, remove the brake release hose at the rotation gearbox. Plug this
hose. Attach a 0 - 3,500(min) PSI pressure gauge to the swing test pressure diagnostic
port. The brake release fitting does not need to be capped.
2. Start engine and run the pump at 2,000 rpm and slowly move the swing lever to full
travel in either direction. The spring applied swing brake will stall the swing motor and
cause the hydraulic system to go over relief. Look at the pressure gauge; see previous
pressure table for proper setting.
NOTE: Move the handle back to neutral immediately after taking the reading to
prevent excessive heat.
3. Make proper adjustments by turning the adjusting screw clockwise for more pressure
and counterclockwise for less. Be sure to torque the jam nut to 10 ft.lbs and reinstall
the acorn nut.
PROCEDURE FOR ADJUSTING THE WINCH RELIEF

The system relief should be set only when the oil in the hydraulic system is warm or at
operating temperature. Attach a 0 - 3,500(min) PSI pressure gauge to the swing test
pressure diagnostic port.
1 WINCH TEST PRESSURE PORT 2 WINCH ADJUST

1. With control levers in neutral position, raise pump RPM to 2,000.

Service / Parts
2. With either the winch engaged in a deadman pull, or the winch-up workport capped
and plugged, move the winch handle to the up direction. Hold the handle until the
system goes over relief.
LEAVE ALL OTHER CONTROL LEVERS IN THE NEUTRAL POSITION.

3. Check the reading at the winch test Diagnostic port.
NOTE: Move the lever to the neutral position immediately after taking the
pressure reading to avoid excessive heat.
4. Make proper adjustments to relief by turning the relief adjustment clockwise for more
pressure and counterclockwise for less pressure. Be sure to retighten the jam nut to
10 ft.lbs. and install the acorn nut.

Outrigger and Cylinder Maintenance and Troubleshooting
Outrigger Position Sensors
If your crane is equipped with Outrigger Position Sensors-the rear outrigger box will contain
(2) two proximity sensors for determining the location of each outrigger beam at full
extension. Each sensor has an air gap to maintain to operate properly and send signals to
the Load Moment Indicator (LMI). When each rear outrigger beam is fully extended a green
light on the operator's Outrigger control box and will illuminate for both the left side and
right side. Visually inspect sensors for damage, the condition of related wiring harness
connections and dirt / debris that could inhibit the sensor signal or proper air gap.
SENSOR CHARACTERISTICS & SETTING

OUTPUT TYPE NORMALLY CLOSED
SENSING RANGE 15 MM
MINIMUM OPERATING VOLTAGE 6 VDC
MAXIMUM OPERATING VOLTAGE 48 VOLTS
MINIMUM OPERATING TEMPERATURE -40C
MAXIMUM OPERATING TEMPERATURE +70C
MINIMUM LOAD CURRENT 200 MA
AIR GAP SETTING 0.12" (3.2 mm)

Service / Parts
1. Proximity Sensor-Outrigger Position

Hoist Cylinder
HOW TO ANALYZE HOIST CYLINDER PERFORMANCE
The HOISTcylinder should hold up the boom and load with a minimal amount of drop-off.
The cylinder is equipped with a counterbalance type holding cartridge in the base of the
cylinder.
DO NOT REMOVE THE CARTRIDGE IN THE BASE END OF THE TOPPING

WITHOUT THE BOOM BEING UNLOADED AND IN A SUPPORTED CONDITION.
REMOVING THE CARTRIDGE WITH THE BOOM IN AN UNSUPPORTED
CONDITION WILL CAUSE THE BOOM TO DROP INSTANTLY AND
UNCONTROLLABLY.
TRAPPED PRESSURE IN CYLINDER CAN FORCEFULLY EJECT CARTRIDGE.

MAKE SURE PRESSURE IS RELIEVED BEFORE REMOVING A CARTRIDGE.
NEVER STAND BEHIND A CARTRIDGE WHILE REMOVING IT.
To test the cylinder for holding, the following procedure should be used:
NOTE: With the outriggers extended, mark each outrigger leg. These marks should
be checked at the end of the test procedure below to determine if any outrigger is
the cause of the movement noted.
With the boom fully retracted and at a 50-60° angle, attach a weight equivalent to the rated
load and raise the load 2 feet off the ground. Accurately measure and record the distance
from the ground. Shut off the engine and move the control levers to release the hydraulic
pressure trapped in the hoses. The load should not drop more than 1/2” in 10 minutes. If it
drops more than the amount allowed, the following troubleshooting steps should be
performed:
A leaking cylinder will generally fall into 2 categories:

1. External leaks (usually found around the base of the cylinder).
A. Rated Capacity sensing system hose and fittings.
B. End casting welds.
C. Cartridge O-Rings.
D. Cross-drilled passages and plugs.
2. Internal leaks (bypassing within the cylinder or holding cartridge). There are two thins
that must be checked in order to isolate the source of the leakage:
A. Holding cartridge leaks:
Attach a weight equivalent to the rated load and raise the boom 2-3 inches off the
boom rest. Remove both topping hoses at the control valve. Oil coming from the
boom-up hose indicates a bypass at the counterbalance cartridge. Replace or

Service / Parts
clean the cartridge. Boom must be unloaded and supported before cartridge is
removed.
B. Piston bypassing from base side to rod side:
If oil comes out of the boom-down hose while still engaged in the same test, the
cylinder is bypassing internally and will require internal repairs.
NOTE: This test should be performed with cool oil. If done with very hot oil,
cylinder movement will be caused by thermo contraction of the oil held in the
cylinder
HOIST CYLINDER REMOVAL
Perform the following steps to remove the hoist cylinder:
1. Fully retract and lower the boom onto the boom rest. Disengage the PTO and stop
engine. Actuate hoistlever in both directions to release trapped pressure.
2. Tag and disconnect the hydraulic lines from the topping cylinder.
Hydraulic oil may be under pressure. Loosen fittings very slowly to prevent injury.
These should be plugged or capped to prevent any fluid loss or slippery surfaces
around the work area - also to prevent contamination from entering the hydraulic
system. Plug the resulting open ports of the cylinder to prevent the loss of fluid.
3. Lift against the rod end of the topping cylinder with a hoist or another crane and
remove the rod end pin.
4. With the cylinder balanced in a choker strap, that is attached to a suitable hoist or
other type of lifting equipment, support the cylinder and remove the pin in the cylinder
base. It weighs approximately 5000 lbs. Remove the cylinder, taking precautions to
prevent scratching the paint finish.

BT3870 Hoist Cylinder Assembly
1 CARTRIDGE 6 PISTON NUT

2 PISTON 7 BARREL
3 ROD 8 END GLAND
4 BYPASS ORIFICE 9 RETAINER RING
5 RETAINER PLATE BOLTS 10 RETAINER PLATE

Service / Parts
BT28106 Hoist Cylinder Assembly
1 CARTRIDGE 6 PISTON NUT

2 PISTON 7 BARREL
3 ROD 8 END GLAND
4 BYPASS ORIFICE 9 RETAINER RING
5 RETAINER PLATE BOLTS 10 RETAINER PLATE
HOIST CYLINDER OVERHAUL PROCEDURE

Contact Terex Service Department to receive overhaul information for the cylinder on the
unit. Have the cylinder part number, located on the barrel, available at time of call and the
information will be faxed to you.

Outrigger Cylinder
OUTRIGGER TWO-WAY CHECK SYSTEM
1 Outrigger Pilot Check Holding 4 Extend

Cartridge - LOAD
2 Manual Relaease 5 Retract
3 Outrigger Counterbalance Valve 6 Side Tube
Holding Cartridge - STOW
OUTRIGGER TWO-WAY PILOT TO OPEN CHECK SYSTEM

LOCATED: On each outrigger cylinder.
FUNCTION: Locks outrigger in up position for roading, and down for crane or operation.
Requires internal pilot pressure to operate in either direction.
DO NOT REMOVE CARTRIDGES WITHOUT SUPPORTING THE OUTRIGGERS IN

AN UNLOADED CONDITION. CARTRIDGES DO NOT BLEED OFF PRESSURE
BY REMOVING SLOWLY. THEY CAN EJECT FORCEFULLY IF THE CYLINDER IS
PRESSURIZED. NEVER STAND IN LINE WITH CARTRIDGE WHILE
The main reason for outrigger servicing is leaking. There are two types of leaks: External
and internal.
External leaks may or may not cause the outrigger to drift depending on the source of the
leak. External leaks can usually be located by visually inspecting the cylinder while it is at
full system pressure fully stroked in one direction or the other.
Some things to check might be:

1. Steel lines and fittings.

Service / Parts
2. Welds (Base to cylinder barrel).

3. End gland of cylinder.
4. Cartridge O-Ring.
Internal leaks are more difficult to find and almost without exception require cylinder
removal. Three items must be checked to isolate the leak:
1. The load holding cartridge.
2. Stop engine. Activate outrigger control handle to relieve trapped pressure. Disconnect
extend port hose at valve.
3. If oil runs out of the extend port, the cartridge is bypassing and must be replaced.
TO CHECK LOAD HOLDING CARTRIDGE:
1. Raise truck off ground until tires are clear. If possible, apply maximum payload to flatbed.
2. Stop engine. Disconnect extend port hose at valve.
3. If oil runs out of the extend port, the cartridge is bypassing and must be replaced.
TO CHECK STOW HOLDING CARTRIDGE:
1. Fully retract cylinder.
2. Devise a means of externally trying to extend the cylinder. (Porta-Power or Block &
Tackle).
3. Disconnect retract port hose at valve. If oil runs out of the cylinder, retract pressure
port. The stow holding cartridge is bypassing and must be replaced.
TO CHECK CYLINDER PISTON:
1. Fully extend cylinder.
2. Remove retract cartridge. Use caution, as there will be trapped pressure behind this
cartridge.
3. Pressurize extend port to full system pressure.
4. If oil runs out of retract cartridge bore, piston is bypassing and cylinder must be serviced.
REMOVAL & DISASSEMBLY OF MAIN OUTRIGGERS

1. Extend the outrigger until the shoe just touches the ground.
2. Remove the snap rings from the link pin at the mainframe. The pin should drive out
easily if the leg is properly positioned. If the pin does not drive out easily, reposition
the leg so the pin is not loaded. Allow the links to swing out after the pin is removed..
3. Insert a 7/16” x 14” rod through the links, inner and outer legs. This will support the
links and lock the leg sections together during removal.
4. Disconnect the outrigger hoses, after marking for later reinstallation. Cap hoses and
fittings on cylinder.
5. Insert a 1/2”-13 lifting eye into the boss located on the top plate of the outrigger.

6. Using an overhead hoist attached to the lifting eye, lift the leg into a horizontal position.
NOTE: THIS WILL LEAVE THE LEG VERY HIGH IN THE AIR AND STICKING
OUT APPROXIMATELY 7 FT. DO NOT STAND OR WALK UNDERNEATH THE
LEG WHILE IN THIS POSITION.
7. Remove the snap ring from the upper pivot pin, and with a brass or dead blow
hammer and a drift, drive the upper pin out of the outrigger housing and mainframe
bracket.
8. Raise the hoist until the leg is balanced, then lay the leg on the floor with the link pivot
boss turned down (upside down). Block up under the outrigger leg until the outrigger
shoe clears the floor.
9. Remove the snap rings for the outrigger shoe pin and drive the pin out with a drift.
Remove the shoe and pin.
10. With the assistance of a hoist, pull the cylinder out of the top end of the outrigger
housings.
11. Remove the inner leg and check the weldments thoroughly for any sign of damage,
bending, or welds cracking. Check the wear pads for damage. If pads are worn and
have excessive clearance, they should be shimmed or replaced.
12. Move the cylinder to overhaul bench.
BT3870 Outrigger Cylinder
1 Holding Cartridge 6 Piston Nut

2 Rod 7 Piston
3 Barrel 8 Spacer
4 Thread Cap 9 Gland
5 Set Screw

Service / Parts
BT28106 Outrigger Cylinder
1 Cartridge 6 Piston Nut

2 Piston 7 Barrel
3 Rod 8 End Gland
4 Bypass Orifice 9 Retainer Ring
5 Retainer Plate Bolts 10 Retainer Plate
REASSEMBLY & INSTALLATION OF MAIN OUTRIGGERS

1. Apply a thin film of brush-type anti-seize lubricant (rust inhibitor) to outrigger wear
pads before assembly.
2. Using the proper bolts, attach the top upper and lower wear pads. (Note: It’s a good
idea to use Loctite on these bolts to prevent them from loosening and coming out.)
Using a hoist, slide the inner and outer legs together, and install the upper bottom
wear pad.
3. Have the cylinder extended to approximately mid-stroke. Insert the cylinder into the
outrigger housings and align the cylinder rod eye with the pin hole and shoe holes.
Apply a thin coat of antiseize lubricant (rust inhibitor) to the pin before insertion. Install
pin and snap rings.
4. Using the upper pivot pin as a pilot, line up cylinder base pin hole with upper pivot
hole in the inner leg. After holes are aligned, drive the wedge between the inner and
outer legs again to help maintain alignment.

DO NOT DRIVE THE WEDGE TO THE POINT OF BOWING THE METAL IN THE LEG.
5. Apply a thin coat of anti-seize lubricant (rust inhibitor) to pin before installation.
6. Using the choker strap and hoist, pin the upper leg to the mainframe bracket. Lower
the leg until the links align with the hole in the outrigger leg boss.
7. Install the pin through the links and outrigger boss and install the snap rings.
8. Connect the outrigger hoses. Cycle cylinder several times to full stroke to remove any
air in the cylinder.
REMOVAL & DISASSEMBLY OF AUXILIARY OUTRIGGERS

1. Either work with the rear outriggers over a pit or raise the rear of the truck so that there
is at least 36” of clearance from the bottom of the outrigger shoes.
2. Extend outrigger leg 1” and shut off power.
3. Tag and disconnect cylinder hoses. Cap hoses and fittings on cylinder.
4. Support the outrigger inner leg while removing the upper pin.
5. Swing cylinder inward to rest against inner leg. Carefully lower inner leg out of housing.
6. Remove lower pin snap rings and pin. Using a hoist, pull the cylinder out of the inner leg.
REASSEMBLY & INSTALLATION OF AUXILIARY OUTRIGGERS

1. Extend cylinder 1”-2” and insert into inner leg. Cylinder must be oriented so that ports
are to outside when inner leg is installed.
2. Align rod end with holes in inner leg and install pin and snap rings. Apply a thin coat of
anti-seize lubricant to pin before installation.
3. If slider pad is still inside outer housing (located under doubler strap at lower end of
housing), pry it loose and remove.
4. Inspect slider pad for wear and/or damage. If worn to less than 3/8” thickness over
25% of surface, replace with new pad.
5. Use a heavy gun grease (chassis lube) - applied to back (flat) side of slider pad - to
hold pad in place during reassembly.
6. Install inner leg into outer housing and slide up all the way. Make sure the inner leg is
oriented correctly.
7. Align cylinder end between housing ears with cylinder ports facing out. Apply never-
seize to pin prior to installation.
8. Reconnect cylinder hoses to proper ports.
9. Cycle the leg fully up and down several times to purge air from system and check for
proper operation.

Service / Parts
Extension Cylinder
HYDRAULIC ASSIST EXTENSION SYSTEM
The extension system on the BT extends and retracts by means of a hydraulic cylinder and
a series of cables. The picture below describes the cylinder mounting. The cylinder mounts
into the boom by a series of mounting trunnions shown in the illustrations below. For
further reference, there are descriptions of this and other boom features located in the
BOOM REASSEMBLY on page 259 section.

BT3870 Extension Cylinder Assembly

Service / Parts
A EXTENSION CYLINDER B CYLINDER MOUNT - SIDE VIEW

A1 HYDRAULIC FITTING B1 EXTENSION CABLE ADJUSTMENT
A2 EXTEND CABLE B2 EXTENSION CYLINDER ASSEMBLY
A3 RETAINER BOLTS B3 BASE SECTION CYLINDER MOUNT
A4 HYDRAULIC PLUG B4 SECOND SECTION CYLINDER MOUNT
A5 CARTRIDGE C CYLINDER MOUNT - FRONT VIEW
A6 2ND STAGE TRUNNION C1 BASE SECTION CYLINDER MOUNT
A7 ATTACHMENT LUG C2 SECOND SECTION CYLINDER MOUNT
A8 SHEAVE BRACKET

BT28106 Extension Cylinder Assembly
A EXTENSION CYLINDER B1 EXTENSION CABLE ADJUSTMENT

A1 EXTEND CABLE B2 EXTENSION CYLINDER ASSEMBLY
A2 RETAINER BOLTS B3 SECOND SECTION CYLINDER MOUNT
A3 SHEAVE BRACKET B4 BASE SECTION CYLINDER MOUNT
A4 ATTACHMENT LUG C CYLINDER MOUNT - FRONT VIEW
A5 2ND STAGE TRUNNION C1 BASE SECTION CYLINDER MOUNT
B CYLINDER MOUNT - SIDE VIEW C2 SECOND SECTION CYLINDER MOUNT

Service / Parts
The extension cylinder is equipped with a counterbalance cartridge to hold the rated load
suspended. The system is designed so that when the extension handle is pushed to
extend, the oil is allowed to free-flow through the counterbalance and into a hollow porting
tube in the center of the cylinder rod and into the cylinder’s base. The rod side oil is
bypassed back to the tank through the retract hose as the boom extends.
When the handle is pulled to retract, the oil is routed directly into the rod side of the
cylinder. As pressure is applied, the oil gets into the pilot portion of the counterbalance and
pilots it open, allowing the base oil to be exhausted back to tank. See the following illustration:
1 EXTEND PORT 6 EXTEND LINE

2 PISTON 7 RETRACT LINE
3 COUNTERBALANCE CARTRIDGE 8 BOOM EXTEND/RETRACT VALVE
SECTION
4 PILOT PASSAGE 9 RETRACT FLOW PASSSAGE
5 RETRACT PORT
CHECKING LOAD HOLDING- TELESCOPE CYLINDER
To test the cylinder for holding, the following procedures should be used:
1. Raise boom to maximum angle and extend the boom approximately 3’. Attach a live
load, as used in the topping test, to the load line and lift rated load. Raise the load
4”-5” off the ground. Shut off the engine and move the control lever to release
hydraulic pressure trapped in the hose. The load should not fall more than 1/2” in 10

minutes. If it does fall more than 1/2”, the following troubleshooting procedures should
be followed:
NOTE: This test should be performed with cool oil. If done with very hot oil,
cylinder movement will be caused by thermo contraction of the oil held in the
cylinder
2. A leaking cylinder will generally fall into 2 categories.
A. External leaks (usually found around the base of the cylinder).
i. All weld joints
ii. Cartridge O-Rings
iii. Cross-drilled passages
B. Internal leaks (bypassing within the cylinder or holding cartridge). There are two
things that must be checked in order to isolate the source of the leakage:
i. Holding Cartridge
ii. Piston bypassing from base side to rod side.
DO NOT REMOVE COUNTERBALANCE VALVE UNLESS BOOM IS FULLY

RETRACTED AND SUPPORTED TO PREVENT SUDDEN MOVEMENT.
WHEN LOOSENING FITTINGS, HIGH PRESSURE OIL COULD BE PRESENT IF

COUNTERBALANCE VALVE IS STUCK OPEN OR IF INTERNAL LEAKAGE IS
SEVERE. BOOM SHOULD ONLY BE SLIGHTLY EXTENDED SO THAT SUDDEN
MOVEMENT DOES NOT CAUSE INJURY OR PROPERTY DAMAGE
3. Extend boom 3-4” at maximum angle. Remove both the extend and retract hoses at
the control valve.
A. Oil coming from the boom extend hose indicates bypass from the
counterbalance. Clean or replace the counterbalance.
B. If oil comes out of the boom retract hose while still engaged in this test, the
cylinder is bypassing internally and will require internal repairs.

Service / Parts
Left BT3870 TELESCOPE CYLINDER - 2 CYLINDER ROD

INSIDE VIEW
Righ BT28106 TELESCOPE CYLINDER - 3 SLEEVE
t INSIDE VIEW
1 CARTRIDGE 4 PISTON
CYLINDER OVERHAUL INSTRUCTIONS

For removal of the extension cylinder assembly see Wear Pad Adjustment and
Replacement - Boom Disassembly on page 237.
Contact Terex Service Parts Department to receive overhaul information for the cylinder on
the unit. Have the cylinder part number, located on the barrel, available at time of call and
the information will be faxed to you.

Boom Maintenance, Adjustment and Repair
BT3870 Wear Pad Adjustment and Replacement
1 FRONT TOP WEAR PAD 5* REAR BOTTOM WEAR PAD

2 FRONT BOTTOM SIDE WEAR PAD 6* REAR BOTTOM WEAR PAD
3 FRONT BOTTOM WEAR PAD 7 REAR BOTTOM SIDE WEAR PAD
4 REAR TOP WEAR PAD
* 729-02856 shown, see following page for representation of 729-02857

Service / Parts
REAR BOTTOM WEAR PAD

FRONT TOP WEAR PAD 729-02857
729-02862 Sections:Tip only
Sections:Base, Second
REAR BOTTOM WEAR PAD

729-02856
Sections:Second only
FRONT BOTTOM SIDE WEAR PAD
729-02860
FRONT BOTTOM WEAR PAD

REAR BOTTOM SIDE WEAR PAD
729-02838
729-02872
Sections:Tip, Second
REAR TOP WEAR PAD

729-02836
Sections:Tip, Second
WEAR PAD MINIMUM DIMENSIONS

Boom wear pads must be adjusted and dimensions checked periodically. During
inspection, if any of the indicated dimensions should be outside of what is specified here,
pad shall be replaced. Pad shall also be replaced if pad has suffered extensive damage.
WEAR PAD SPECIFICATIONS
Wear Pad Location Material Height (in) Width (in) Length (in)
MAX MIN
729-02836 Rear Top Plastic 3/4” 5/8” 1 3/4” 7”
*729-02872 Rear Side Plastic 1/2” 3/8” 1 1/4” 6”

*729-02856 Rear Plastic 1 1/8” 1” 3” 3”
Bottom
Sec2
*729-02857 Rear Plastic 1/2” 3/8” 1 1/8” 4”
Bottom Tip
729-02862 Front Side Plastic 1/2” 3/8” 1 1/4” 6”

Top
729-02838 Front Plastic 1/2” 3/8” 1 1/2” 7”
Bottom
729-02860 Front side Cast Iron See Below
Bottom
* these pads need not be checked or replaced on a regular basis, only during a boom tear
down procedure should they be checked and replaced if needed
729-02860 Front Side Bottom wear pad.
1 Shaded area indicates typical wear 2 Worn edge indicates contact with
pattern and maximum wear boom weld
Rotate or replace wear pad when it shows either or both of the following conditions.
- If indicated surface has worn down to lower surface at any point.
- Wear pad shows indications of contact with boom weld.
This pad has two (2) usable wear surfaces. Rotate pad to opposite face and readjust. If
both faces are worn, replace with new wear pad.

Service / Parts
FRONT SIDE BOTTOM WEAR PAD ADJUSTMENT
SHUT OFF ENGINE AND DISENGAGE PTO

1. Extend the boom approximately 10”. Stop the engine and disengage the PTO.
2. Visually inspect the front side wear pads (1). Using the Wear Pad Specifications table
on page 238, check for excessive wear as shown.
3. Adjust set screws (2) until wear pad is tight against bottom plate edge, back screw off
1/4 turn.
4. Check for section alignment, adjust the sections of the boom from side to side until
each section is centered in the adjacent section.
5. Holding the adjustment screw head with a wrench, tighten the adjustment jam nut (3)
to lock the adjustment set screw.
FRONT SIDE TOP WEAR PAD INSPECTION AND REPLACEMENT (SECOND

SECTION)
2. Visually inspect the Front Side Top wear pads (4). Using the Wear Pad Specifications
table on page 238, check for excessive wear.
3. Replace both wear pads if the thickness of either pad has decreased to less than the
minimum.
NOTE: It will be necessary to lift ends of the sections with a hoist to remove the
front bottom wear pads.

1 FRONT SIDE WEAR PADS 3 JAM NUT
2 SET SCREWS 4 FRONT SIDE TOP WEAR PADS
FRONT BOTTOM WEAR PAD INSPECTION AND REPLACEMENT (BASE SECTION)
INSPECTION
1. Extend the boom approximately 10”.
2. Stop the engine and disengage the PTO.
3. Visually inspect the front bottom wear pads (1). Using the Wear Pad Specifications
table on page 238, check for excessive wear.
4. If the thickness of either pad has decreased to less than the minimum, proceed to
replacement.
REPLACEMENT
5. Mark position of retainer nuts on retract cable adjustment studs (2), remove nuts.
BE SURE TO HOLD THE CABLE STUD BY THE WRENCH FLATS PROVIDED TO

PREVENT TWISTING OF THE CABLE. FAILURE TO DO THIS WILL RESULT IN
DAMAGE TO THE CABLES.
6. Remove anchor plate (3) from boom.

7. Remove wear pads

Service / Parts
8. Replace Wear pads
9. Replace retract anchor plate, reinstall retract anchor nuts to mark made in step 5.
FRONT BOTTOM WEAR PAD INSPECTION AND REPLACEMENT (SECOND

SECTION)
1. Extend the boom approximately 10”.
2. Stop the engine and disengage the PTO.
3. Visually inspect the front bottom wear pads (4). Using the table on the previous page,
check for excessive wear.
4. Replace both wear pads if the thickness of either pad has decreased to less than the
minimum.

1 FRONT BOTTOM WEAR PAD (BASE 3 ANCHOR PLATE

SECTION)
2 RETRACT CABLE ADJUSTMENT STUD 4 FRONT BOTTOM WEAR PAD
(SECOND SECTION)

SECOND SECTION - REAR TOP WEAR PAD
WEAR PAD ADJUSTMENT AND REPLACEMENT

1. From fully retracted, extend the boom approximately 18 inches.
2. Shut Off Engine and Disengage the PTO

3. Remove Wear Pad Service Cover (1) on top rear of boom.

4. Remove Cam Retaining Screw (2) and Cam (3).
5. Loosen and remove Wear Pad Bracket Screws (4), Wear Pad Bracket (5) and Wear
Pad (6).
6. Inspect Wear Pad for the following criteria:
- Less than minimum thickness (see Wear Pad Specifications table on page 238).
- Less than minimum width (see Wear Pad Specifications table on page 238).
- Uneven wear
- Heavy distortion
- Cracking
- Breaking
7. If the pad suffers from any of the above, replace the Wear Pad with a new one.
8. Reinstall Wear Pad, Wear Pad Bracket and Wear Pad Bracket Screws into the boom.
9. Reinstall Cam and Cam Retaining Screw.
10. Rotate the Cam, using a socket and breaker bar on the Cam Driver (7) until all play is
removed from Wear Pad.
11. While maintaining pressure on the Cam Driver, tighten Cam Retaining Screw to lock
Cam Driver in place.
12. Check Wear Pad for play to ensure all play has been removed.
13. Tighten all 4 Wear Pad Bracket Screws.
14. Repeat steps 3 through 13 on opposite wear pad.
15. Reinstall Wear Pad Service Cover.

Service / Parts
Expanded view shows pad position and mounting
1 WEAR PAD SERVICE COVER 5 WEAR PAD BRACKET

2 CAM RETAINING SCREW 6 WEAR PAD
3 CAM 7 CAM DRIVER
4 WEAR PAD BRACKET SCREWS
TIP SECTION - REAR TOP WEAR PAD
WEAR PAD ADJUSTMENT AND REPLACEMENT

2. Shut Off Engine and Disengage PTO.

3. Remove Wear Pad Service Cover (1) on top base of boom.

4. Loosen and remove Wear Pad Bracket Screws (2), Wear Pad Bracket (3) and Wear
Pad (4).
5. Inspect Wear Pad for the following criteria:
- Less than minimum thickness (see Wear Pad Specifications table on page 238)
- Less than minimum width (see Wear Pad Specifications table on page 238)
- Uneven wear
- Heavy distortion
- Cracking
- Breaking
6. If the pad suffers from any of the above, replace the Wear Pad with a new one.
7. Reinstall Wear Pad, Wear Pad Bracket and Wear Pad Bracket Screws into the boom.
8. Push wear pad bracket outward until all play is removed from wear pad.
9. Tighten all 4 screws holding wear pad bracket into place.

Service / Parts

2 WEAR PAD BRACKET SCREWS 4 WEAR PAD
BOOM REMOVAL
ANY LIFTING DEVICE USED SHOULD HAVE CAPACITY OF AT LEAST 10,000 LBS.

1. Fully retract boom and lower onto the boom rest.
2. Disengage the PTO and stop engine.


Service / Parts
Motor shift two speed winch shown. Combined flow winch will be similar.
1 TELESCOPE CYLINDER HYDRAULIC 2 WINCH HYDRAULIC CONNECTIONS

CONNECTIONS
3. Tag and disconnect the hydraulic lines from the telescope cylinder (1) and winch (2) at
fittings indicated below. Cap the hoses and plug the cylinder ports. The winch fittings
can be removed with an appropriately sized wrench.

4. Lift towards the rod end of the topping cylinder with another crane or suitable hoist
and remove the rod pin. Lower the rod end of the cylinder down onto a block wedged
between the bottom of the cylinder and the turret.
DO NOT DROP THE TOPPING CYLINDER DOWN AGAINST THE TURRET, OR

THE BARREL OF THE CYLINDER MAY BE DAMAGED. SUPPORT THE END OF
THE CYLINDER SO IT CANNOT MOVE ACCIDENTALLY.
5. Using chains or cables with a capacity of 10,000 lbs. Connect to the lifting lugs on top
of the base boom and lift slightly. This will be center of gravity for the boom assembly.
6. Remove the boom hinge pin.
7. Lift the boom onto stands or blocking. Stands or blocking must have the capacity of
holding approximately 10,000 lbs and be installed close to both ends of boom base to
provide a sturdy support preventing any unexpected movement. Secure the boom to
these stands.
BOOM DISASSEMBLY PROCEDURE

These instructions assume that the winch assembly has been removed after the boom was
removed from the boom truck. Any stands or lifting devices used should have the capacity
of holding approximately 10,000 lbs. Stands or blocking must be installed close to both
ends of the base boom to provide a sturdy support. The boom should be secured to these
stands to prevent any unexpected movement.
It is best if the stands are shaped in such a way that the keel shape of the boom is matched
so it will not tilt or fall over during servicing. This will also prevent the boom from being

Service / Parts
damaged due to self weight. (Large timbers with a “V” cut to match the bottom side of the
boom make excellent stands.)
NOTE: To avoid confusion when reassembling the boom, keep wear pads and
shims in matched sets as they are removed. Keep bolts, capscrews, lock washers,
and nuts with the parts they retain.
1 EXTEND CABLE ANCHOR 8 CABLE RETAINER SCREWS

2 EXTEND CABLE 9 RETRACT CABLE SHEAVE
3 EXTEND CYLINDER TRUNNION 10 CABLE RETAINER
4 WEAR PAD SERVICE COVER 11 RETRACT CABLE
5 EXTENSION CYLINDER 12 RETRACT CABLE ANCHOR
6 EXTENSION SHEAVE 13 RETRACT ANCHOR BRACKET
7 EXTEND CYLINDER CAP
1. Remove nuts from Retract Cable Anchor on front of base section.
BE SURE TO HOLD THE CABLE STUD BY THE WRENCH FLATS PROVIDED TO

PREVENT TWISTING OF THE CABLE. FAILURE TO DO THIS WILL RESULT IN
DAMAGE TO THE CABLES.
2. Remove Retract Anchor Bracket from front of base section.

3. Remove all front wear pads between base and second sections. This includes side
top, side bottom and bottom wear pads.

NOTE: Bottom wear pads will require that the weight of the second and tip
sections be lifted to free the wear pads for removal.
4. Remove extension cable nuts from rear of base section.
5. Remove Extend Cylinder Cap from rear of base section.
6. Remove Wear Pad Service Cover from the top of the base section.
7. Remove the rear side top wear pads between base and second sections.
8. Remove rear side bottom wear pads.
9. Remove rear bottom wear pads between base and second sections.
NOTE: Bottom wear pads will require that the weight of the second and tip
sections be lifted to free the wear pads for removal.
10. Slide second and tip sections out of base section.
11. Remove bolts from Extend Cylinder Trunnion.
12. Remove tabs from Extend Cylinder Trunnion.
13. Remove Cable Retainer Screws from around Retract Cable Sheaves.
14. Using zip ties, anchor Retract Cable ends to the Extend Cylinder rod.
15. Using zip ties, anchor Extend Cables to Extend Cylinder rod.
16. Remove front bottom wear pads from between second and tip section.
17. Remove extend cylinder and tip section from second section.
18. Extend cylinder will rest on retract cable anchor pin.
19. Remove extend cable anchor plate by pulling it out through the back of the boom.
20. Remove rear side wear pads from tip section.
21. Support cylinder and remove retention cable anchor pin.
22. Remove rear bottom wear pad from tip section.
23. Slide extend cylinder assembly from tip section.

Service / Parts
BT28106 Wear Pad Adjustment and Replacement
Front View (left) and Rear View (right)
The following notes will apply anytime replacement or removal of any wear pads are
involved. Use shims under the pads to attain proper clearances between boom sections.
See dimension notes on above illustration for clarification.
Dim A Rear top wear pads and adjacent boom sections: 1/16”
maximum clearance.
Dim. B Front and rear side wear pads and adjacent boom
sections: 1/32” maximum clearance.
Dim. C Front bottom 3rd and 4th stage boom sections: 3/4”
Dim. D Front bottom 2nd and 3rd stage boom sections: 1 9/16”
Dim. E Front bottom base boom and 2nd stage boom sections:
1 5/8”.
Front View on the dimension notes illustration above.
1. When making adjustments, remove the shims from one side and add same shims to
the other side. Dimension B in Section A no longer applies. Clearance for the bottom
wear pads that make contact with the keel sections at the boom tip end sections must
be checked to insure shimming is consistent from one side to the other side and both
lower pads make contact with the keel surface of the boom.
2. Apply a thin film of brush-type anti-seize lubricant on the base, 2nd, and 3rd stage
boom sections where pads make contact, on inside surfaces. On outer boom tip

surfaces use lithium based grease. The width and length of lubrication needs to be full
wear pad contact area. Use a heavy duty temperature resistant lubricant; Military
Spec: MIL-A-9070 Bossert P/N 76764 or equivalent.
3. Apply a thin film of lithium grease (Fleet Industries Stock #1454-SW-G) to the outside
surfaces of side plates and bottom plates on 2nd, 3rd, and 4th stage booms where
wear pads make contact. Width and length of lubrication to be full wear pad contact
area. Apply grease before assembly of boom sections.
1 Wear Pad Inspection Location: Rear of

Base Boom
WEAR PAD REPLACEMENT CHART
PART NUMBER NEW SIZE MINIMUM THICKNESS

729-02235 3/4” 5/8”
729-02236 3/4” 5/8”
729-02640 3/4” 5/8”
NOTE: Wear pad bolts should be either shimmed or shortened as necessary to

prevent contact or scraping of the adjacent boom section. Serious damage to boom
weldment may occur if these steps are not followed.

BOOM IS TELESCOPED WHILE HANDS OR TOOLS ARE IN HOLES
REAR TOP WEAR PADS

1. Fully retract the boom so the top rear wear pads on the 2nd stage are accessible
through the holes in the top of the base section.
2. Measure the thickness of the rear top wear pads on the top of the 2nd stage boom.
Replace both wear pads if worn too much to maintain the proper clearance, to avoid
unnecessary boom droop.

Service / Parts
3. Measure the clearance between the rear top wear pads and the adjacent section.
4. If necessary, loosen the mounting screws and add shims under the wear pads to
provide the clearance given in the wear pad clearance chart.
1 Wear Pad 3 Rear of 2nd Stage Boom

2 Screws 4 Shims
NOTE: Shims come in three thicknesses as noted below.
PART NUMBER DESCRIPTION THICKNESS

787-00238 SHIM 0.04
*787-00308
787-00239 SHIM 0.063
*787-00309
787-00240 SHIM 0.10
* 787-00310
NOTE: * These shims used with wear pad # 729-02640 top rear 2nd stage boom.
5. Securely tighten the mounting screws after the shims are installed. Use Loctite 242 on
all bolts.
6. Extend the boom so top rear wear pads on the 3rd stage are accessible through the
holes in the base and 2nd stage.
7. Repeat Rear Top Wear Pads, Steps 1 through 5 for the 3rd section.
NOTE: Rear side wear pads can only be adjusted or replaced when the boom is
disassembled.

FRONT BOTTOM AND SIDE WEAR PADS

BOOM IS TELESCOPED WHILE HANDS OR TOOLS ARE IN HOLES
2. Measure the thickness of the front side wear pads. Replace all of the wear pads for
the respective section if the thickness of any side wear pad has decreased to the
minimum dimension given in the previous table. Check for metal to metal contact
between the pad fastener and boom.
3. Adjust the stages of the boom from side to side until each stage is centered in the
adjacent section.
4. Measure the clearance between front side wear pads and the adjacent section.
5. If necessary, loosen the mounting screws after the shims are installed.
6. Securely tighten the mounting screws after the shims are installed.
NOTE: Mounting screws for the side wear pads must not rub against the
adjacent section. If necessary, add washers behind the head of the mounting
screws so screws fully engage the nuts in the wear pads but not rub against the
section.
7. Measure the thickness of the front bottom wear pads and replace both wear pads for
the respective sections if the thickness of either pad has decreased to the dimension
given in the table above.
front bottom wear pads. The front bottom wear pads on the base boom are
fastened to the retraction cable mounting pads; the mounting pad must be
removed from the end of each retraction cable to gain access to the wear pad.
Readjust the retraction cables after reinstalling mounting pads. See Extension and
Retraction Cable Adjustment sections of Boom Cable Adjustment Procedure on page
279.
8. Measure the clearance between the sections as in pad clearance chart.
9. If necessary, add shims under the wear pads to provide the clearance given above.
Make sure both pads are making contact with the keel of the boom. Shim as high as
possible to achieve even contact on both pads without contacting side slider pads.
10. Securely tighten the mounting screws after the shims are installed.

Service / Parts
BOOM REMOVAL
ANY LIFTING DEVICE USED SHOULD HAVE CAPACITY OF AT LEAST 10,000 LBS.
1. Fully retract boom and lower onto the boom rest. Disengage the PTO and stop engine.
2. Tag and disconnect the hydraulic lines from the cartridge block on the end of the
telescope cylinder. Cap the hose and plug the cylinder ports. Remove winch hoses
and cap and plug.
3. Lift against the rod end of the topping cylinder with another crane or suitable hoist and
remove the rod pin. Lower the rod end of the cylinder down onto a block.
DO NOT DROP THE TOPPING CYLINDER DOWN AGAINST THE TURRET, OR

THE BARREL OF THE CYLINDER MAY BE DAMAGED. SUPPORT THE END OF
THE CYLINDER SO IT CANNOT MOVE ACCIDENTALLY.
4. Using slings with legs at least 4’ long and a capacity of 10,000 lbs. connect to the
lifting lugs on top of the base boom and lift slightly. This will be center of gravity for the
boom assembly.
5. Remove the boom hinge pin.
6. Lift the boom onto stands or blocking. Stands or blocking must have the capacity of
holding approximately 10,000 lbs and be installed close to both ends of boom base to
provide a sturdy support preventing any unexpected movement. Secure the boom to
these stands.
BOOM DISASSEMBLY PROCEDURE

These instructions assume that the winch assembly has been removed after the boom was
removed from the boom truck. Any stands or lifting devices used should have the capacity
of holding approximately 10,000 lbs. Stands or blocking must be installed close to both
ends of the base boom to provide a sturdy support. The boom should be secured to these
stands to prevent any unexpected movement.
It is best if the stands are shaped in such a way that the keel shape of the boom is matched
so it will not tilt or fall over during servicing. This will also prevent the boom from being
damaged due to self weight. (Large timbers with a “V” cut to match the bottom side of the
boom make excellent stands.)
NOTE: To avoid confusion when reassembling the boom, keep wear pads and
shims in matched sets as they are removed. Keep bolts, capscrews, lock washers,
and nuts with the parts they retain.
1. Remove the cartridge block, by cautiously unscrewing the four socket head
capscrews. Use caution as there may be some pressure trapped in the cylinder.
MAKE SURE THAT THE O-RINGS DO NOT FALL OUT OF THE CARTRIDGE BLOCK.
2. Remove the inspection cover on top of the base boom. Remove the lock and jam nuts
from the four 3rd stage extend cables protruding from the cylinder mounting at the
rear of the base boom. Secure the cables to the cylinder through the inspection hole in

the top of the base boom. BE SURE TO HOLD THE CABLES BY THE WRENCH
FLATS PROVIDED ON THE ENDS TO PREVENT TWISTING. FAILURE TO DO THIS
WILL RESULT IN DAMAGE TO THE CABLES.
3. Remove the nuts from the four 3rd stage retract cables at the front of the base boom.
Lift the front of the 3rd stage boom to unload the lower pads. Remove the side, top,
and lower wear pads as well as cable blocks. BE SURE TO HOLD THE CABLES BY
THE WRENCH FLATS PROVIDED ON THE ENDS TO PREVENT TWISTING. FAILURE
TO DO THIS WILL RESULT IN DAMAGE TO THE CABLES.
4. Carefully slide the 2nd, 3rd, and 4th stages out of the boom. BE SURE THAT THE
RETRACT CABLES ARE PULLED OUT WITH THE BOOM ASSEMBLIES TO AVOID
DAMAGING THEM.
Temporarily reinstall the cartridge block onto the extension cylinder to avoid the
possibility of contamination entering the cylinder porting.
5. Remove the retract cable guides from the bottom of the 2nd stage boom, and stretch
the 4th stage cables out behind the boom to prevent them from being kinked.
6. Remove the nuts on the 4th stage extension cables from the mounting plate on the
upper rear end of the 2nd stage boom. BE SURE TO HOLD THE CABLES BY THE
WRENCH FLATS PROVIDED ON THE ENDS TO PREVENT TWISTING. FAILURE TO
DO THIS WILL RESULT IN DAMAGE TO THE CABLES.
Supporting the weight of the extension cylinder with a hoist, remove the 12 bolts
holding the trunnion mount plates to the 2nd stage boom.
Push the trunnion mount plates inboard on the cylinder trunnions.

7. Remove the jam nuts on the 4th stage retraction cables and remove the upper, side
and lower front wear pads from the front of the 2nd stage boom. Remove the cable
mounting blocks also.
8. Lift the cylinder and extend tube assembly as high as possible, and remove the 3rd
stage retract cable sheave pins, sheaves, and cable guides. Remove the 3rd stage
retraction cables and inspect for rust, kinks, and any signs of damage.
9. Carefully remove the 3rd and 4th stage assemblies from the 2nd stage boom. The
cylinder and extend tube assembly should remain with the 3rd and 4th stage booms.
10. Remove the retract cable retainers from the bottom of the 3rd stage boom. Remove
the buck eyes from the retract cable pins and remove the cable guides and sheave
assemblies. Lay the retract cables straight out behind the booms to prevent kinking or
damage to the cables.
11. Again, raise the base of the extension cylinder as high as possible to gain working
room, and remove the three 1/2” bolts anchoring the four 3rd stage extend cables to
the extend/retract cable bracket.
12. Remove the four bolts holding the extend/retract bracket to the extend tube assembly.
Remove the extend/retract bracket assembly.
13. After devising some means to secure the extend cables to the cylinder barrel, slowly
remove the cylinder assembly from the 4th stage and extend tube assembly. Stop

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about half of the way out and find the approximate center of gravity of the cylinder
assembly and reposition the sling. Set cylinder assembly on work stands and
disassemble if necessary. Check the extend cables thoroughly for wear and damage.
14. Raise the extend tube assembly as high as possible and remove the 4th stage extend
cable anchors in the rear bottom of the 4th stage boom. After securing the 4th stage
extend cables to the extend tube, slowly remove the extend tube assembly. Stop
about half of the way out and find the approximate center of gravity and reposition the
sling. Put the assembly on a work stand and disassemble if necessary

Boom Assembly
These instructions assume that the boom is in a completely disassembled condition. The re-
assembly will be carried out in several stages of sub-assembly starting with the extend
cylinder assembly first
EXTEND CYLINDER ASSEMBLY

.
1 EXTEND CABLE 6 EXTEND CABLE

2 CYLINDER 7 HEAD UNIT INSTALLATION BOLTS
3 WEAR PAD 8 SHEAVE PIN
4 HEAD UNINT 9 ROPE EXTEND SHEAVES
5 LUG
IMPORTANT NOTE:
Before beginning assembly of the Boom Extend Mechanism, the extend cylinder needs to
be extended approximately 34 inches, this can be accomplished by connecting the cylinder
to a hydraulic pressure source or by uncapping the hydraulic ports and mechanically
pulling the cylinder rod out to the 34 inches. Do not scratch or mar the polished portion of
the rod cylinder.

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Assemble the extension cylinder assembly as follows:
NOTE: Use Loctite 2440 on ALL bolts during assembly.
Telescope Cylinder Assembly
1. Install top and bottom Wear Pads

(4 total) on Sheave Head Unit.
Assemble the sheave head unit to
cylinder using the 1/2-13 x 1 1/8
Gr. 8 bolts with flat washers.

2. Install bearing inner races into the
(2) rope extend sheaves. Insert
sheave assembly as shown.
3. Install sheave pin. Install snap

rings and grease fittings.
4. Place Extend Cables around

Sheaves. Install spacers and bolts
as shown.
NOTE: BEFORE PROCEEDING,

BE SURE THAT YOU HAVE
EXTENDED THE CYLINDER ROD
PER THE INSTRUCTIONS ABOVE.
5. Secure Extend Cables to Extend Cylinder with large gauge zip ties as shown,
spacing should be every 4-6 ft.

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CABLES MUST NOT BE CROSSED DURING ANY PORTION OF THIS

ASSEMBLY
BOOM ASSEMBLY - TIP SECTION
TIP SECTION ASSEMBLY
1. Starting with the tip section, assemble sheaves, bearing races, pins, spacer
and snap rings to the boom tip.

2. Insert Extend Cylinder Assembly
into Tip Section as shown. Clip
and remove cable ties as
assembly is inserted. DO NOT
allow cables to cross or tangle.
3. Install Retract Cable Eyes on

Retract Anchor Rod.

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4. Install Retract Anchor Rod and Cable Assembly into Tip section anchor points.
5. Install Rear Wear Pads, side and bottom (4 Total) on Tip Section. Bottom wear
pads require hex head screws, side wear pads require flat head screws.
6. Lower Cylinder to rest on Retract Anchor Rod. Install Extend Cable Anchor
Plate by sliding Extend cables into slots in plate. Seat plate by putting tension
on the upper end of the Extend Cables.

7. Correct positioning of Extend cable anchor plate and cable after installation.
NOTE: Cable length and cylinder extension will vary from what is shown.
BOOM ASSEMBLY - SECOND SECTION
SECOND SECTION ASSEMBLY
1. Assemble Retract Cable Sheave assembly as shown below, be sure to use a

single spacer on the inside of each bearing. The number of spacers used on

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the outside of each bearing will need to be adjusted so the sheaves are
centered and fit snugly into the brackets.
2. Test- fit Retract Cable Sheave

assembly as shown. Remove
Assembly and set aside before
moving on to step 3.
3. After coiling and anchoring the retract cables to the rod of the extend cylinder
assembly. Insert base end of Tip section into the tip end of the Second section.
4. As the tip section approaches full insertion, the Extend Cylinder Trunnion must
be checked for alignment with it’s anchor point as shown in the cutout view
below. The cylinder will most likely need to be lifted slightly to align trunnion.

5. Once the Cylinder Trunnion is fully seated, insert the locking tabs behind the
trunnion, engaging the slots in the mount, and secure with bolts. Install
previously configured Retract Cable Sheave assembly.
6. Release Retract cables from their tied position and route them over the second
section retract sheaves.

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7. Insert cable guide shoulder bolts (4) to retain retract cables on sheaves.
8. Install cable guide wear pads (2) on the rear bottom of the second section,
routing retract cable through pad groove, install bolts from inside the section.

9. Install side wear pads (2) on second section as shown using (4) flat head bolts.
BOOM ASSEMBLY - BASE SECTION
BASE SECTION ASSEMBLY
1. Install second and tip section assembly into base section. During insertion be
sure that retract cables (1) do not cross or tangle and that they are not pinched
between the sections.
2. Install lower front wear pads (2) and riser blocks, be sure to pay attention to the
orientation of the riser blocks. Thinner riser blocks (3) install in the second
section, thicker blocks (4) install in the base section. Secure with bolts (4+4) as
shown. Shorter bolts (5) secure second section wear pads, longer bolts (6)
secure base wear pads.

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3. Install Retract Anchor plate, route Retract Cable Lugs through plate, secure
loosely with nuts. Secure plate with bolts and washers into wear pad riser blocks.
4. Align and insert the cylindrical cylinder base into the boom cylinder boss of the
base section. DO NOT pry on the polished portion of the cylinder rod. Secure
the cylinder using the base plate, being sure to align and insert the tab as

shown and installing bolts with washers. After checking for crossed or tangled
cables, route Extend Cable Lugs through anchor holes and secure with nuts.
BOOM ASSEMBLY - WEAR PAD INSTALLATION
Base and Second Section

1. Install upper front wear pads (1) by inserting from front and loosely install bolts. Insert
lower side wear pads (2) through holes in the side of the base and second sections as
shown.

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2. Install Lower wear pads.

a. Insert lower wear pad anchor plate through gusset holes as shown.
b. Install lower wear pad adjustment bolts through anchor plate.
3. Secure wear pads.

a. Use the lower wear pad adjustment bolts to center boom sections.
b. Install shims for upper wear pads, be sure that slot straddles both retaining bolts.
Shims should be installed in such a way as to minimize clearance without binding
sections.
c. Tighten upper wear pad bolts.
d. Adjust lower wear pad bolts until pad contacts boom, back each screw off 1/2
half turn and lock in place with locknut.

NOTE: Steps 2 and 3 need to be performed on base and second sections, both sides.
Second Section - Rear Top Wear Pad Installation and Adjustment

2. Shut Off Engine and Disengage the PTO.

3. Remove Wear Pad Service Cover (1) on top rear of boom.

4. Install Wear Pad (6), Wear Pad Bracket (5) and Wear Pad Bracket Screws (4) into the
boom.
5. Install Cam (3) and Cam Retaining Screw (2).
6. Rotate the Cam, using a socket and breaker bar on the Cam Driver (7) until all play is
removed from Wear Pad.
7. While maintaining pressure on the Cam Driver, tighten Cam Retaining Screw to lock
Cam Driver in place.
8. Check Wear Pad for play to ensure all play has been removed.
9. Tighten all 4 Wear Pad Bracket Screws.

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Expanded view shows pad position and mount.

2 CAM RETAINING SCREW 6 WEAR PAD
3 CAM 7 CAM DRIVER
4 WEAR PAD BRACKET SCREWS
Tip Section - Rear Top Wear Pad Adjustment and Replacement

2. Shut Off Engine and Disengage PTO.

3. Remove Wear Pad Service Cover (1) on top base of boom.

4. Install Wear Pad (4), Wear Pad Bracket (3) and Wear Pad Bracket Screws (2) into the
boom.
5. Push wear pad bracket outward until all play is removed from wear pad.
6. Tighten all 4 screws holding wear pad bracket into place.

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2 WEAR PAD BRACKET SCREWS 4 WEAR PAD
BOOM ASSEMBLY REFERENCE - EXTEND AND RETRACT MECHANISMS

The following diagrams display the Extend and Retract mechanisms in hopes to further
clarify their proper assembly and function, please use these diagrams as reference for any
questions you may have about the assembly or function of these mechanisms.

1 EXTEND CABLE ANCHOR 6 RETRACT CABLE
2 EXTEND CABLE 7 CABLE RETAINER
3 EXTENSION CYLINDER 8 EXTEND BRACKET
4 EXTENSION SHEAVE ASSEMBLY 9 RETRACT BRACKET
5 CABLE RETAINER SCREWS 10 RETRACT ANCHOR BRACKET
RETRACT MECHANISM
1 RETRACT ANCHOR TIP SECTION 5 RETRACT SHEAVE

2 RETRACT CABLE 6 RETRACT CABLE GUIDE
3 RETRACT ANCHOR PLATE 7 ANCHOR BLOCK BASE SECTION
4 RETRACT ANCHOR SECOND
SECTION

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EXTEND MECHANISM
1 EXTEND ANCHOR BASE SECTION 5 EXTEND CYLINDER ANCHOR

SECOND SECTION
2 EXTEND CABLE 6 EXTEND ANCHOR PLATE
3 EXTEND SHEAVE 7 EXTEND ANCHOR TIP SECTION
4 EXTEND CYLINDER ANCHOR BASE 8 EXTEND SHEAVE ASSEMBLY
SECTION

BT3870 Boom Cable Adjustment Procedure
1. Loosen the adjusting nuts on the 3rd stage extend cables so that the cables are slack.
Be sure to hold the cable from rotating as the nuts are turned.
2. Extend the boom approximately 3’ to 4’ and remove power. Working through the
access hole in the top of the base boom section, remove the lock nuts and loosen the
jam nuts on the 4th stage extend cables until the cables are slack.
3. Fully retract the boom and put a match mark “A” on the side of the 2nd stage boom,
flush with the end of the base boom section. Put a match mark “B” on the side of the
3rd stage boom flush with the end of the 2nd stage boom.

access hole in the base section, check the tension of the 3rd stage extend cables by
hand. TIghten the adjusting nut on the loosest cables until all four cables are tensioned
equally.
5. Torque the adjusting nut on the 3rd stage retract cables to 25 ft.lbs. (four cables)
6. Fully retract the boom while watching the 2nd and 3rd stages. Note which stage stops
first.
7. Extend the boom approximately 6” and repeat previous step, noting which boom
section stops first.
8. Determine the remaining stroke to fully retract the boom as follows:
A. If the 3rd stage stopped first:
Measure the remaining stroke between match mark A on the 2nd stage boom
section and the base boom.
B. If the 2nd stage stopped first:
Measure the remaining stroke between match mark B on the 3rd stage and the
end of the 2nd stage.
9. If the remaining stroke is greater than 1/8” proceed as follows:
A. Extend the boom approximately 3’ to 4’ and remove power.
B. If the 3rd stage stopped first:
i. Loosen the adjusting nut on each retract cable 1 1/2 turns for each 1/8” of
remaining stroke.
ii. Tighten the adjusting nut on each extend cable 2 turns for each 1/8” of
remaining stroke.
C. If the 2nd stage stopped first:

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i. Loosen the adjusting nut on each extend cable 2 turns for each 1/8” of
remaining stroke.
ii. Tighten the adjusting nut on each extend cable 1 1/2 turns for each 1/8” of
remaining stroke.
10. Repeat steps 16-19 until the remaining stroke is 1/ 8” or less.
11. Recheck the torque on the retract cables and assure that they are still at 35 ft.lbs.
12. Cycle the boom two or three more times and check that all boom sections are
properly synchronized per the above instructions. If not synchronized, check which
sections require adjustment and perform the proper adjustment procedure to correct.
13. Repeat step above until the boom is properly synchronized.
14. Recheck the torque on all the retract cables and insure that all adjusting nuts are
installed and jammed.
15. Install the inspection cover on the top of the base boom section.


BT28106 Boom Cable Adjustment Procedure
SHUT OFF ENGINE AND DISENGAGE PTO. DO NOT STICK HANDS OR TOOLS
IN BOOM SECTIONS UNTIL THE ENGINE IS SHUT OFF AND PTO IS
DISENGAGED. FAILURE TO DO THIS MAY RESULT IN SEVERE PERSONAL
INJURY, INCLUDING LOSS OF HANDS OR FINGERS!
1 Second Stage Boom 5 Fourth Extend Tube

2 Third Stage Extend Anchor 6 Third and Fourth Stage Retract Anchors
3 Fourth Stage Extend Cables 7 Fourth Retract Cable
4 Third Stage Extend Cables 8 Third Retract Cable
1. Loosen the adjusting nuts on the 3rd stage extend cables so that the cables are slack.
Be sure to hold the cable from rotating as the nuts are turned.
access hole in the top of the base boom section, remove the lock nuts and loosen the
jam nuts on the 4th stage extend cables until the cables are slack.
3. Fully retract the boom and put a match mark “A” on the side of the 2nd stage boom,
flush with the end of the base boom section. Put a match mark “B” on the side of the
3rd stage boom flush with the end of the 2nd stage boom.
equally.
5. Torque the adjusting nut on the 3rd stage retract cables to 25 ft.lbs.
6. Fully extend the boom and check tension of the 4th stage extend cables. Tighten the
adjusting nut on the loosest cable until the cables are equally tensioned.
7. Fully retract the boom while watching the 4th and 3rd stages. Note whether the 4th
stage stops before the match mark B aligns itself with the end of the second stage boom.

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8. Extend the boom approximately 6” and repeat previous step as slowly as possible.
Remove power as soon as the 4th stage stops or as soon as match mark B is fully
aligned, whichever occurs first..
A. If the 4th stage boom stopped first:
Measure the remaining stroke between match mark on the 3rd stage boom and
the end of the end of the second stage boom.
B. If match mark B aligned itself first,:
Measure the remaining stroke between the 4th and 3rd stages (at the bottom,
where the 3rd stage tip contacts the 4th stage tip weldment).
B. If the 4th stage stopped first:
remaining stroke.
ii. Tighten the adjusting nut on each retract cable 1 1/2 turns for each 1/8” of
remaining stroke.
11. Repeat steps 7 -10 until the remaining stroke is 1/ 8” or less.
12. Recheck the torque of the adjusting nut on the 4th stage retract cables and assure
that the torque setting is still at 25 ft.lbs..
13. Reinstall the locking nuts removed earlier from the 4th stage retract cables and lock
down against the jam nuts.
equally.
15. Torque the adjusting nut on the 3rd stage retract cables to 25 ft.lbs. (four cables)
16. Fully retract the boom while watching the 2nd and 3rd stages. Note which stage stops
first.
17. Extend the boom approximately 6” and repeat step 16. Note which boom section
stops first.
A. If the 3rd stage stopped first:
Measure the remaining stroke between match mark A on the 2nd stage boom
section and the base boom.
B. If the 2nd stage stopped first:

Measure the remaining stroke between match mark B on the 3rd stage and the
end of the 2nd stage.
B. If the 3rd stage stopped first:
i. Loosen the adjusting nut on each retract cable 1 1/2 turns for each 1/8” of
remaining stroke.
ii. Tighten the adjusting nut on each extend cable 2 turns for each 1/8” of
remaining stroke.
C. If the 2nd stage stopped first:
remaining stroke.
ii. Tighten the adjusting nut on each extend cable 1 1/2 turns for each 1/8” of
remaining stroke.
20. Repeat steps 16-19 until the remaining stroke is 1/8” or less.
21. Recheck the torque on the retract cables and assure that they are still at 35 ft.lbs.
22. Cycle the boom two or three more times and check that all boom sections are
properly synchronized per the above instructions. If not synchronized, check which
sections require adjustment and perform the proper adjustment procedure to correct.
23. Repeat previous step until the boom is properly synchronized.
24. Recheck the torque on all the retract cables and insure that all adjusting nuts are
installed and jammed.
25. Install the inspection cover on the top of the base boom section.
SHUT OFF ENGINE AND DISENGAGE PTO. DO NOT STICK HANDS OR TOOLS
IN BOOM SECTIONS UNTIL THE ENGINE IS SHUT OFF AND PTO IS
DISENGAGED. FAILURE TO DO THIS MAY RESULT IN SEVERE PERSONAL
INJURY, INCLUDING LOSS OF HANDS OR FINGERS!

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Rotation Gear and Gearbox

Removal/Installation of Rotation Gear and Gearbox
REMOVAL OF ROTATION GEAR & GEARBOX
THE BOOM MUST BE REMOVED BEFORE ATTEMPTING THE FOLOWING

PROCEDURE
1. Thoroughly steam clean unit in rotation gear area.

2. Remove the rotation gearbox from its mounting and lay it on the control console. It is
not necessary to disconnect the hydraulic lines when performing this step unless
complete removal of the gearbox is desired.
3. Disconnect grease tubes from fittings on swing bearing, 2-places.
4. Remove Bolts holding the turret to the rotation bearing.
5. Remove the turret from the rotation bearing.
6. Remove rotation bearing mounting bolts.
7. Remove the rotation bearing from the turret.
INSTALLATION OF ROTATION BEARING & GEARBOX

1. Both the turret and mainframe bearing mounting surfaces must be carefully inspected
for flatness and smoothness. Remove all burrs and ridges that might prevent the
bearing race from sitting flat. Maximum surface flatness tolerance is .006” TIR. in any
90° segment.
NOTE: Before installing bearing, use the procedure on the following page to
inspect the bearing.
2. Place the rotation bearing on the mainframe, being sure to place the bearing side, with
the inner ring protruding, against the mainframe. Rotate the inner ring so the loading
plug is 90° to the left of the rotation gearbox.
NOTE: Left corresponds to the operator’s left side when standing at the controls.
3. Assemble bearing to the mainframe using new bolts and hardened flat washers. Do
not begin torquing bolts until all bolts are in place. Torque the bolts to 100 ft.lbs first,
then final torque the bolts to 350 - 380 ft.lbs. See bolt torque sequence chart below.
4. Connect grease hoses to inner ring grease ports. This enables greasing of the rotation
bearing from fitting located on the sides of the mainframe.
5. Lift the turret into position over the rotation gear. Mounting surfaces must be clean
and flat. Orient the turret so that all mounting holes in the turret align with the
mounting holes in the bearing. For certain machines, the rotation bearing will have
more mounting holes that the turret, position the turret so that there are equal
numbers of unused holes to each side.

6. Install new bolts and hardened flat washers to fasten the turret to the rotation bearing.
Do not begin torquing until all the bolts are in place. Torque the bolts for the turret to
100 ft.lbs first then final torque to 350 - 380 ft.lbs. See bolt torque sequence chart below.
Inner ring/Mainframe torque sequence
Outer ring/Turret torque sequence

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Inspection of Rotation Bearing Clearance

1. It is not feasible to make an analysis of the condition of the rotation gear while it is on
the unit. There are too many variables involved for this to be accurate.
2. A bearing may cause a problem in the operation of the boom truck or the confidence
of the operator long before it would be deemed structurally unsafe.
To properly check the radial clearance of the rotation gear, it must first be removed from
the boom truck and placed on a heavy flat table. Remove all dirt and grease from the
outside of the gear and secure it to the table with clamps, assuring that the inner raceway
rotates freely after clamping it to the table.
As shown in the figure below, attach a large “C” clamp in position #1, and tighten just
enough to take all the slack out of the raceway. Install a dial indicator as close to position
#1 as possible, and set it to “0”.
As shown in the figure below, attach a large “C” clamp in position #1, and tighten just
enough to take all the slack out of the raceway. Install a dial indicator as close to position
#1 as possible, and set it to “0”.
Remove the “C” clamp and attach at clamp location #2 and again tighten just enough to
take up the slack in the two raceways. Look at the dial indicator, noting the amount of
change in the reading. This measurement is the radial clearance of the bearing. The
following bearing clearances should be observed.

Radial Clearance Check Procedure
1 "C" Clamp 4 Clamp Position #2

2 Rotation Gear 5 Dial Indicator
3 Clamp Position #1
1. Any new bearing being installed on a Terex boom truck should not have more than .
004 - .007 radial clearance.
2. Any bearing taken off a unit which has .030 - .050 radial clearance should be screened
carefully for roughness while rotating. If excessively rough, the bearing should be
disassembled and thoroughly inspected for damage in the raceways, and for rust or
pitting.

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Backlash Adjustment
The rotation mechanism should be checked periodically for any signs of looseness or
excess lash between the gears.
The procedure for setting backlash is as follows:

1. Locate the high spot on the rotation gear. This spot is marked with yellow paint at the
time of manufacture of the bearing. You will be able to see this spot by wiping away
some of the gear grease. The high spot can also be located with a dial indicator by
rotating the bearing assembly without the swing gearbox installed.
2. Be sure the high spot is aligned to the pinion; turn the eccentric cam ring until the
gears are in mesh and there is no clearance at all.
3. Install a dial indicator as shown in the following illustration and set to 0.
1 Pinion 3 Mainframe Top Plate

2 Dial Indicator
4. Loosen the mounting bolts holding the gearbox just enough so that the gearbox may
be moved when the eccentric cam ring is turned.
5. Rotate the cam ring slowly until the reading is .020 - .025.
6. Remove the gearbox bolts one at a time and apply new LOC-TITE to the threads. Re-
torque the bolts to 280 - 300 ft.lbs.

Coat rotation gearbox pilot and mainframe pilot bore with anti-seize compound to
prevent rust and binding of the eccentric ring.

Appendix
Conversion Tables
DECIMAL AND METRIC EQUIVALENTS OF FRACTIONS OF AN INCH
Fractions of an Inch Decimals of an inch Millimeters

1/64 0.0156 0.397
1/32 0.0313 0.794
3/64 0.0469 1.191
1/16 0.0625 1.588
5/64 0.0781 1.985
3/32 0.0938 2.381
7/64 0.1094 2.778
1/8 0.1250 3.175
9/64 0.0406 3.572
5/32 0.1563 3.969
11/64 0.1719 4.366
3/16 0.1875 4.762
13/64 0.2031 5.159
7/32 0.2188 5.556
15/64 0.2344 5.953
1/4 0.2500 6.350
17/64 0.2656 6.747
9/32 0.2813 7.144
19/64 0.2969 7.541
5/16 0.3135 7.937
21/64 0.3281 8.334
11/32 0.3438 8.731
23/64 0.3594 9.128
3/8 0.3750 9.525
25/64 0.3906 9.922
13/32 0.4063 10.319
27/64 0.4219 10.716
7/16 0.4375 11.12
29/64 0.4531 11.509
15/32 0.4688 11.906
31/64 0.4844 12.303

Appendix
Fractions of an Inch Decimals of an inch Millimeters

1/2 0.5000 12.700
33/64 0.5156 13.097
17/32 0.5313 13.494
35/64 0.5469 13.891
9/16 0.5625 14.287
37/64 0.5781 14.684
19/32 0.5938 15.081
39/64 0.6094 15.478
5/8 0.6250 15.875
41/64 0.6406 16.272
21/32 0.6563 16.688
43/64 0.6719 17.085
11/16 0.6875 17.462
45/64 0.7031 17.859
23/32 0.7188 18.256
47/64 0.7344 18.653
3/4 0.7500 19.050
49/64 0.7656 19.447
25/32 0.7813 19.843
51/64 0.7969 20.240
13/16 0.8125 20.637
53/64 0.8281 21.034
27/32 0.8438 21.430
55/64 0.8594 21.827
7/8 0.8750 22.224
57/64 0.8906 22.621
29/32 0.9063 23.018
59/64 0.9219 23.415
15/16 0.9375 23.812
61/64 0.9531 24.209

31/32 0.9688 24.606
63/64 0.9844 25.003
1 1.0000 25.400

WEIGHTS AND MEASURES
LIQUID MEASURE (U.S.)
4 gills = 1 pint
2 pints = 1 quart
4 quarts = 1 gallon
7.48 gallons = 1 cu. ft.
240 gallons of water = 1 Ton
340 gallons of gasoline = 1 Ton
LIQUID MEASURE (METRIC)
1 litre = 0.0353 cu. ft.

1 litre = 0.2642 gallon
1 litre = 61.023 cu. in.
1 litre = 2.202 lbs. of water(62oF.)
1 cu. foot = 28.32 litres
1 gallon = 3.785 litres
1 cu. inch = 0.0164 litre
MEASURES OF WEIGHTS (U.S.)
16 ounces = 1 pound
2000 pounds = 1 short ton
2240 pounds = 1 long ton
100 cu. feet = 1 register ton
40 cu. feet = 1 U.S. shipping ton
MEASURES OF WEIGHTS (METRIC)
1 gram = 0.0353 ounce

1 kilogram = 2.205 lbs.
1 ounce = 28.35 grams
1 pound = 0.454 kilogram
1 ton = 0.907 metric ton

Appendix
CIRCULAR MEASURE
60 seconds = 1 minute
60 minutes = 1 degree
90 degrees = 1 quadrant
360 degrees = 1 circumference
ELECTRICAL UNITS
1 kilowatt = 1.34 H.P.

1 horsepower = 746 watts
SURVEYOR’S MEASURE
7.92 inches = 1 link

100 links = 66 feet
or 4 rods
or 1 chain
80 chains = 1 mile

Average Weight of Materials
All weights are shown in units of Lb. per Cu. Ft.
METALS, ALLOYS, ORES
Aluminum, Cast- 165

Hammered
Brass, Cast-Rolled 534
Bronze 509
Copper, Cast-Rolled 556
Gold, Cast-Hammered 1205
Iron, Gray-Cast 442
Iron Slag 172
Lead 710
Manganese 475
Mercury 847
Nickel 537
Steel 481-489
Tin, Cast-Hammered 459
Tungsten 1200
Zinc, Cast-Rolled 440
MASONRY
Ashlar Masonry * 143-162
Ashlar Masonry * 143-162 Rubble 137-156

Masonry *
Dry Rubble Masonry * 110-130
*Granite, Syenite, Gneiss, Marble,
Limestone, Sandstone, Bluestone
Brick Masonry 103-128
Concrete Masonry 100-128
Portland Cement 196
Portland Cement, Loose 94
Lime, Gypsum, Loose 53-64
Mortar, Lime, Set 103
WOOD
WOOD Cedar 22

Appendix
Fir, Douglas 32
Oak 42-54
Pine, Oregon 32
Pine, Southern 38-42
Redwood 2
Spruce 28
Black Walnut 37
EARTH
Clay, Dry 63
Clay, Damp, Plastic 110
Clay & Gravel, Dry 100
Earth, Dry Loose 76
Earth, Dry Packed 95
Earth, Moist Loose 78
Earth, Moist Packed 96
Earth, Mud Flowing 108

Earth, Mud Packed 115
Riprap, Limestone, 80-105
Sandstone, Shale
Sand, Gravel, Dry 90-105
Loose
Sand, Gravel, Dry 100-120
Packed
Sand, Gravel, Wet 126
EXCAVATIONS IN WATER
Sand or Gravel 60
Sand or Gravel & Clay 65
Clay 80
River Mud 90
Soil 70
Stone Riprap 65

STONE, QUARRIED, PILED
Basalt, Granite, Gneiss 96
Limestone, Marble, 95
Quartz
Sandstone 82
Shale 92
Greenstone, Hornblend 107
MISCELLANEOUS
Water, 4o C. 62.4
Water, 100o C. 59.8
Paper 58
Glass, Common 162
Petroleum 45-54
Coal, Anthracite 47-5
Coal, Bituminous 40-54
Coal, Coke 23-32

Appendix
Torque Specs -SAE & Metric

Appendix
Man Basket Installation & Operation Manual

Greer Insite Operation's Manual
Your crane may be set up with a Greer Insite or a BT510 (RCI) Rated Capacity Indicator
system. Determine which model you have installed. Completely read the attached manual
in the Appendix section before attempting to operate the crane.

Appendix
BT510 Operator's Manual

Your crane may be set up with a BT510 (RCI) Rated Capacity Indicator system or a 3B6
Slim (LMI) Load Moment Indicator. Determine which model you have installed. Completely
read the attached manual in the Appendix section before attempting to operate the crane.

Notes

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Table of Contents

Anti-Two Block Components......................................................... 106

BT3870 Wear Pad Adjustment and Replacement ......................... 237

iv P/N 12261-533 REVISED: October 2011

• THE BT3870S MODEL CAN BE INSTALLED ON EITHER TANDEM OR SINGLE AXLE

THE BT28106 BOOM TRUCK FROM TEREX COMES

• AT NO TIME CAN A BT28106 BE INSTALLED ON A SINGLE REAR AXLE CHASSIS.

P/N 12261-533 REVISED: October 2011 5

6 P/N 12261-533 REVISED: October 2011

P/N 12261-533 REVISED: October 2011 7

ANSI/ASME B30.5 – Mobile & Locomotive Crane (Latest Version)

These standards may be purchased by:

This manual is copyrighted. It shall not, either in whole or in part, be reproduced,

8 P/N 12261-533 REVISED: October 2011

P/N 12261-533 REVISED: October 2011 9

Bulletin Distribution and Compliance

10 P/N 12261-533 REVISED: October 2011

Manufacturer contact information:

P/N 12261-533 REVISED: October 2011 11

Transfer of Machine Ownership

12 P/N 12261-533 REVISED: October 2011

THIS SYMBOL MEANS YOUR SAFETY IS INVOLVED! READ, UNDERSTAND,

ANSI/ASME B30.5 - Mobile & Locomotive Crane (Latest Version)

These standards can be purchased from:

American Society of Mechanical Engineers

P/N 12261-533 REVISED: October 2011 13

SAFETY ALERT SYMBOL

MACHINE DECAL HAZARD CLASSIFICATION SYMBOLS

A multi-tier hazard classification system is used on machine decals to communicate

1. DANGER - Indicates an imminently hazardous situation which, if not avoided,

2. WARNING - Indicates a potentially hazardous situation which, if not avoided,

3. CAUTION - Indicates a potentially hazardous situation which, if not avoided,

4. NOTICE - Notice used without a safety alert symbol indicates a hazardous

14 P/N 12261-533 REVISED: October 2011

CRUSH HAZARD Keep clear of moving machine.

Safety Alert Symbol Use personnel lift in

Skin Injection From Use Cardboard or Wood to

Falling From NO RIDERS

Hand Entanglement Keep Hands Clear of Winch

P/N 12261-533 REVISED: October 2011 15

ENTANGLEMENT Keep away from fan and belt

Explosion / Burn Keep all open flames and

DO NOT OPERATE equipment

BURN HAZARD No smoking. No flame. Stop

BURN HAZARD Allow surfaces to cool before

16 P/N 12261-533 REVISED: October 2011

Maintain 3-Point Contact when

Two blocking the Check Anti-two Block System.

Electrical Shock / Stay Sufficient Distance From

P/N 12261-533 REVISED: October 2011 17

18 P/N 12261-533 REVISED: October 2011

P/N 12261-533 REVISED: October 2011 19

BT28106 Safety Sign Locations

BT28106 Boom Safety Sign Locations- Curbside

20 P/N 12261-533 REVISED: October 2011

P/N 12261-533 REVISED: October 2011 21

BT28106 Mainframe Turret Safety Sign Locations