2002 Terex TA35 / TA40 Articulated Dump Truck Maintenance Manual (SM776/777)

This 2002 Terex TA35 and TA40 maintenance manual covers articulated dump trucks with Detroit Diesel Series 60 engines and ZF 6WG 310 transmissions. The cover identifies reference SM776/777 and revision SM 1451 Rev 7, 10-02.

Text search and diagram detail: Service text is searchable, but lettering within the wiring sheets is not. The contents pages have section links; there are no embedded PDF bookmarks. Small wiring labels need zooming for detailed reading.

• Engine and fuel systems: Engine removal and installation, DDEC III/IV fault-code interpretation, electronic foot pedal service, and fuel-flow testing.

• Transmission diagnosis: EST-37 fault-code tables, clutch pressure measuring points, AEB adjustment displays, and transmission removal and installation.

• Axles and chassis: POWR LOK differential repair, ring-and-pinion setup, third differential lock adjustment, planetary hubs, and articulation and oscillation pivot service.

• Steering and body hydraulics: Flow amplifier and steering valve repair, main pump inspection, body control valve testing, and steering and hoist cylinder rebuilding.

• Brake repair: Closed-center system pressure tests and bleeding, brake pump overhaul, accumulator charging, and treadle valve testing and adjustment.

• Cooling and cab systems: Kysor DST fan tests, radiator and air-to-air charge cooler service, cab and seat removal, and R-134a air-conditioning diagnosis.

This manual is suited to experienced heavy-equipment technicians equipped for hydraulic bench testing and lifting major assemblies.

DDEC and EST-37 Diagnosis

The DDEC diagnostic charts relate flashed codes to PID, SID, and FMI references. Coverage explains active and stored faults, the diagnostic request switch, diagnostic data reader use, ECM protection functions, and electronic unit injector operation.

The transmission section maps the integral hydraulic retarder, clutch solenoids, and oil circulation. EST-37 tables pair fault codes with controller responses and checks. AEB display tables cover clutch filling adjustment; the tool list identifies AEB starter 15273664.

Repair limits: Internal engine and transmission overhaul procedures require the component manufacturers' separate service manuals. This publication covers removal, mounting work, routine service, and the diagnosis described above.

Production Changes and Wiring Coverage

The wiring sections distinguish pre-June 1999 DDEC III systems from the DDEC III/IV configurations used from June 1999 onward. Component and cable designations, fuse lists, and the ZF 6WG 310/EST-37 harness interface support electrical fault tracing.

Separate sections address changes to transmission oil coolers in August 1999, brake and treadle valve arrangements in November 1999, and hydraulic tanks and lubrication schedules in December 1999. These distinctions help match the diagram and test procedure to the installed components.

Differentials, Pivots, and Hydraulic Circuits

Front and rear frame documentation includes articulation bearing and oscillation bushing work. Differential procedures cover bearing preload, ring-and-pinion contact patterns, and third differential lock setup. The POWR LOK instructions warn that changing the matched component sequence or shimming can cause differential failure.

The steering system schematic, steering valve sectional view, and body hoist schematics connect valve operation with pressure test points. Body diagrams show Raise, Hold, Lower, and Float positions; diagnosis charts distinguish pump supply problems, control valve faults, and cylinder seal leakage. Pilot supply valve service is covered separately.

Brake Testing and Component Repair

Brake manifold valve service and nitrogen accumulator procedures accompany treadle valve bench tests. Braking schematics show engine shutdown, service brake application, and park/emergency brake application, with front and rear circuit test points.

The brake sections warn that J1703 brake fluid damages rubber components in this system, which uses specified hydraulic oil. Follow the manual's precautions for stored hydraulic pressure, supported bodies, and work around the articulation joint.

Cooling, Cab Work, and Service References

The Kysor DST fan section provides static and dynamic checks and identifies the fan drive as non-serviceable. Cab coverage includes R-134a leak testing, evacuation, charging, and troubleshooting.

Reference material includes fluid capacities, lubrication schedules, wear limits, and standard and component-specific torque tables. Listed tools include helical gear tool 15269088 and pivot thrust nut tool 15269101; drawings also provide dimensions for cylinder service tools.

A Preview of Pressure, Torque, and Wear Data

These examples are a small selection of the manual's service specifications. The steering and body hydraulic sections specify a system relief pressure of 172 bar (2,500 lbf/in²), alongside pressure test locations and adjustment information.

For articulation work, the upper pivot pin retaining nut is specified at 1,425 Nm (1,050 lbf ft). The service brake inspection section gives a disc replacement threshold of 16 mm (0.63 in) or less, based on average disc thickness.

Printable PDF and Included Pages

This 488-page PDF is one printable English file containing 446 technical pages, one cover page, two introductory safety pages, two contents pages, and 37 blank or intentionally blank pages. All are included in the total.