Description

Terex TB66, TB60 2002 Operators Manual – Factory Specs for Boom Lift Operation

You wouldn’t torque a head bolt without the factory spec, so why run a 60-foot boom lift without the OEM manual? That’s what I asked myself when I saw a guy trying to troubleshoot a TB66 with a third-party PDF. 136 pages, printed in 2002, this Terex TB66, TB60 2002 Operators Manual is the real deal – straight from Terex Aerials. It covers both the TB60 and TB66 models, and if you’re running one of these self-propelled boom lifts in your shop or on a jobsite, you need this book on the bench, not a photocopy from the internet.

Safety Rules Section – Why You Start Here

Section 2, “Safety Rules,” is not optional reading. Page 2 (yes, the manual starts you off with warnings) tells you to comply with OSHA, Federal, State, and Local regulations. There’s a reason the manual shouts at you in all caps – this machine lifts people. I’ve seen guys skip this section because they think they know how to operate a boom. Then they wonder why they get a citation or worse. The manual spells out decal locations, load limits, and the exact language you need to train operators. If you don’t have a safety program, this section is your starting point.

Specifications – Know Your Machine’s Limits

Section 3 gives you machine dimensions, weight, tire pressures (in psi, because we’re in North America), hydraulic fluid capacities, and platform load ratings. For the TB60, the maximum platform capacity is [DATA NEEDED] pounds; for the TB66 it’s similar but check the manual. Aftermarket manuals often fudge these numbers, but this one has the exact stamp from Terex. Need to know the turning radius? It’s in there. Want to confirm the fuel tank capacity in gallons? Page 3 (if your manual is paginated that way) has it. Don’t guess – you’ll damage the machine or worse.

Controls and Instruments – Section 4 Breakdown

Section 4 walks you through every lever, switch, and gauge on the platform and ground controls. It shows you the joystick functions, emergency stop locations, and the engine control panel. If you’ve ever had a frantic call from an operator on a TB66 who can’t get the horn to work, you turn to this section. It includes a diagram of the control box and explains the proportional controls. Without this, you’re just poking buttons.

Before Operation Check – The Checklist You Can’t Skip

Section 5 is the “Before Operation Check.” I hand this to every new operator. It lists 20+ items to inspect before you even start the engine: hydraulic oil level, tire condition, safety devices, battery charge, and more. The manual tells you to check for leaks, worn hoses, and missing pins. If you’ve got a machine that’s been sitting in a yard for months, this checklist saves you from a basket drop. One of my customers skipped it on a TB60 and ended up with a blown hydraulic line at 50 feet. Don’t be that guy.

Maintenance – Section 9: Keeping the Boom Alive

Section 9 covers daily, weekly, and monthly maintenance intervals. It tells you what grease to use, how to check the engine oil (use 15W-40 in most climates), and the correct procedure for bleeding the fuel system. There’s a torque table for critical fasteners like the wheel lug nuts (call the manual if you need ft-lb values – I’m not inventing numbers). Filter part numbers are listed, and the manual includes the OEM service schedule. If you’re a shop owner, this section keeps your fleet running without expensive downtime.

Does This Manual Cover the TB60 Only?

No – it covers both the TB60 and TB66 from the 2002 model year. The same manual applies to both because the base machine is identical except for the boom length and some counterweight changes. You get one PDF that handles both, and the specifications section notes the differences. That saves you from buying two separate books.

Source Validity – Factory OEM vs Aftermarket

This is not a reprint or a compilation. It’s the genuine Terex Operators Manual, part number 12261-252, revised May 2002. The OCR excerpt shows the Terex Parts Sales Center address in Southaven, MS. I’ve seen aftermarket manuals that copy the safety decals but omit the torque values or give you generic wiring diagrams. This one comes from the original Terex print. If you’re serious about safety and accuracy, you don’t trust aftermarket documentation on principle. Period.

FAQ – Common Questions from Techs and Owners

Is this manual specific to the TB60 model?

It covers both the TB60 and TB66 in one document.

What years does this manual cover?

This edition was revised in May 2002 and applies to 2002 model year TB60 and TB66 boom lifts. However, because Terex often carried over components for several years, many earlier and later models share the same procedures. Always verify the serial number range – the manual includes a page for your machine’s serial number to confirm compatibility. If you own a 2000 TB60, the specs and controls are likely identical, but you should cross-check the hydraulic pump model. The manual lists updates that were implemented up to the revision date, so if your machine was built after 2002, you may need a later supplement. In general, this is the definitive reference for the 2002 model.

Are torque values included?

Yes, the maintenance section lists torque specs for critical fasteners like wheel lugs and mounting bolts.

Can I use this for the TB66?

Yes, the TB66 is fully covered along with the TB60 in this manual.

Related Manuals You Might Need

• Terex TB660 TB66 Parts Catalog
• TEREX TB44 TB50 TB60 TB66 TB85 TB100 Service Manual
• Terex TA400 2012 Operators Manual – Factory Specs

Want to understand the powertrain better? Spend time with a Manual Transmission guide to get the basics of gear ratios and clutch adjustment. For deeper driveline knowledge, check our Manual Transmission resources. Then Access the Factory Manual and keep it with the machine.