Terex TR45, TR60 Operators Manual – Factory Operation & Safety Specs

You don’t run a 45-ton dump truck by feel. You run it by the book – the factory book. If you’re pulling a Terex TR45, TR60 Operators Manual onto the bench or into the cab of a TR45 or TR60 without the printed procedures, you’re gambling with downtime and safety. I’ve seen operators smoke a clutch pack because they guessed the brake release sequence. That mistake costs more than this manual.

This is the original Terex Equipment Limited publication, part number OHS.754/781-750/782 Rev. 3, November 2000. It runs 134 pages of operation, safety, and daily maintenance. Spanish language – but the diagrams and torque tables don’t need translation. Every spec comes from the same engineers who built the truck.

Operator Responsibility and Safety Warnings

Page 3 of this manual states in bold: “Only properly trained personnel are authorized to operate this vehicle.” That’s not a suggestion – it’s a legal requirement under the EC Machinery Directive 98/37/EEC. The manual covers daily pre-start checks, parking brake application, and the exact sequence for dumping loads. Missing a step here can roll a 60-ton rig. The safety section includes the EC Declaration of Conformity on page 5, signed by Chief Engineer Tom McIlwain. That document tells you the machine meets 87/404/EEC, 89/336/EEC, and 98/37/EEC. If you’re operating in North America, you need this document to confirm compliance upgrades.

Controls and Operating Sequence

Factory operators manuals walk you through every lever, pedal, and gauge. The TR45 and TR60 share the same cab layout, but the load ratings differ. You get the gear selector logic, retarder operation, and the emergency steer backup. The manual uses both metric and imperial units where applicable – something aftermarket reprints often botch. Need the charge pressure for the Allison transmission? It’s in there. The section on manual transmission operation is brief but correct. If you need a deeper dive on gearbox fundamentals, check the Manual Transmission entry on Wikipedia. But for factory shift points, stick to page 42 of this book.

Daily Inspection and Lubrication Points

A 10-minute walk-around prevents a 10-hour rebuild. This manual lists every grease fitting, oil check point, and filter element for both models. It tells you which SAE grade to use in the hydraulic tank – and what happens if you mix fluids. The lubrication chart is printed on fold-out pages, so you can pin it in the tool room. I’ve watched guys ruin a $4,000 steering cylinder because they skipped the kingpin grease interval. Don’t be that guy.

Why Factory OEM Beats Aftermarket Copies

The difference between this manual and a photocopied PDF is the difference between a genuine Terex bolt and a hardware store Grade 5. The aftermarket manuals I’ve seen frequently screw up the brake valve adjustment specs – they copy from an earlier revision and miss the safety updates. This document is Rev. 3, November 2000, printed by Terex Equipment Limited in Motherwell, Scotland. It carries the original order reference number 15272708 on page 2. You don’t get that from a third-party scan. For parts breakdowns, pair this operators manual with the TEREX TR40 TR45 2010 Parts Catalog or the TEREX TR60 2002 Parts Catalog. If your TR60 is a later build, the TEREX TR60 2006 Parts Catalog covers updates.

Who Needs This Manual?

If you own or operate a Terex TR45 or TR60, you need this. Equipment dealers, rental yards, and mine site mechanics also keep it in the dispatch office. Beginners should read the safety section twice before starting the engine. The manual assumes you have basic mechanical skills – but it doesn’t assume you’ve seen a 500-hp diesel before. It explains the pre-heat cycle, the air dryer purge, and the body-up warning light sequence. For the transmission fundamentals, see Manual Transmission background. But for real procedures, this is the only source you trust.

Is this manual in English?

This is the factory-issued Spanish language operators manual. English versions were produced separately and may be available on this site. The diagrams, torque tables, and numerical specifications are language-independent.

Does it include repair procedures?

No. This is an operators manual – it covers operation, safety, daily inspection, and preventive maintenance. For major repairs you need the service and repair manual. Check related manuals above.

What page has the torque specs?

The torque table for hydraulic fittings appears on page 73. Wheel nut torque is specified in the maintenance section. All values are factory Terex data.

Can I use this for a TR70?

No. The TR45 and TR60 share a common platform. The TR70 has different powertrain and brake systems. You need the dedicated TR70 operators manual.

You’ve seen what happens when someone runs a dump truck without the factory book – blown transmissions, overheated brakes, and worse. Don’t add your truck to that list. Download the Factory Manual now and put the OEM procedures on your bench.