2002 Terex TA35 / TA40 Articulated Dumptruck Service Manual (SM776/777)

• Covers the complete 2002 Terex TA35 and TA40 articulated dump truck range equipped with the Detroit Diesel Series 60 engine and ZF 6WG 310 transmission.
• Original OEM publication SM776/777 (issued October 2002) containing 488 pages of technical detail, including 18 component-specific exploded views, 4 electrical schematics, and 6 torque-specification tables.
• Serves as the master reference for both the 35-ton and 40-ton haulers, specifically documenting the transition to DDEC electronic control systems.
• Easily print individual pages, diagrams, or torque tables to take right out to the shop floor.

Workshop-Focused System Documentation

Whether you are tackling a routine inspection or a major overhaul, this manual outlines the exact architecture of your hauler. It breaks down the front and rear frame chassis construction, including crucial servicing data for the articulation and oscillation pivots. You get a clear look at the cooling system setups for the Series 60 engine, alongside the complex hydraulic circuits running the steering, body hoists, and braking systems. It even maps out the integration of the hydraulic retarder within the ZF transmission. Since this is an instant download, you won't lose days waiting on shipping when dealing with immediate hood, cowl, or cab mounting realignments. Note that while this manual provides comprehensive technical specifications, working on heavy machinery carries inherent risks; always ensure safety protocols are followed and consult certified professionals before undertaking complex diagnostic work.

Specification and Reference Data

Cut the guesswork out of your maintenance schedule with exact OEM reference tables. This publication delivers precise fluid capacities, operational pressures, and fastener torque values straight from Terex. For example, hydraulic system pressures are locked in at 172 bar (2,500 lbf/in²) for the steering and body circuits. Transmission pressures are further categorized by clutch-engagement solenoid to significantly speed up your troubleshooting process. Need engine specs? The manual lists maximum torque ratings of 1,830 Nm (TA35) and 1,966 Nm (TA40), a shared cooling system capacity of 54 liters, and precise cylinder head bolt torque values for your rebuilds. Heavy structural work is also covered, with articulation pivot fasteners—like the primary pin nuts—clearly specified at 1,425 Nm.