2009 TEREX TA25 / TA27 / TA30 Articulated Dump Truck Maintenance Manual & Training Guides (P/N 15503430)

This Terex maintenance publication (P/N 15503430, February 2009 revision) covers the TA25, TA27, and TA30 articulated dump trucks. It is combined with four Terex product-training documents on Cummins Quantum Controls, the hydraulic system, ZF Transmission Controls, and Specifications & Operator Controls.

• Engine and cooling: Engine removal and installation, mounting inspections, cooling fan checks, air-cleaner servicing, radiator work, and transmission and hydraulic oil cooler service.

• Transmission diagnosis: ZF 6WG 260 and 6WG 310 RPC removal and installation, fault-code tables, electrical testing, pressure checks, and AEB clutch calibration.

• Axles and suspension: Planetary hub disassembly, differential drive-head service, cross-axle differential lock diagnosis, and conventional and independent front suspension procedures.

• Hydraulics and steering: Main hydraulic pump adjustments, main valve troubleshooting, steering orbitrol valve overhaul, cylinder service, and body-hoist fault diagnosis.

• Brakes: Oil-immersed multi-disc brake service, wear checks, circuit bleeding, nitrogen accumulator charging, tandem-circuit treadle valve service, and parking brake adjustment.

• Electrical controls: Wiring diagrams, Quantum fault diagnostics, hydraulic ECU checks, TOC8 programming, and engine-to-transmission CAN-bus testing.

• Frame and cab: Articulation and oscillation pivot repairs, frame and alloy-steel casting welding procedures, hood supports, cab mounting, and air-conditioning service.

It is suited to heavy equipment mechanics and workshop technicians familiar with lifting equipment, hydraulic pressure testing, and electronic diagnostic tools.

Engine Service and Quantum Controls

The Quantum Electronic Fuel System section explains sensor inputs, engine protection, diagnostic codes, and the maintenance light monitoring system. It distinguishes active faults from historical codes accessed with Cummins INSITE.

Engine coverage includes removal, reinstallation, mounts, and external service. Internal engine service and repair are referred to the engine manufacturer's service manual. The supplemental training also covers QSC controls for the TA25 (A874); this is not a QSC engine overhaul manual.

Cooling and air-cleaner sections include fan diagnosis, intake restriction limits, and service intervals.

ZF Transmission Diagnosis and Calibration

Fault-code tables pair TCU reactions with checks, while the training material explains RPC clutch control, sensor circuits, gear selection, and retarder operation. Tool references include AEB Starter P/N 15273664, ZF TestMan P/N 15501299, and diagnostic software P/N 15501300.

Transmission removal, installation, external component work, and calibration are covered. Internal gearbox service and repair are referred to the transmission manufacturer's service manual.

Axle, Suspension and Brake Repair

Exploded planetary hub views accompany disassembly, inspection, and assembly procedures. Differential sections include bearing adjustment and shim selection, supported by axle bolt and nut torque tables.

Separate conventional and IFS front suspension sections, serial-specific rear suspension illustrations, and rear brake pressure tables help match the repair procedure and test specification to the truck's build. Brake coverage includes accumulator discharge and charging, treadle valve troubleshooting, and hydraulic circuit bleeding.

Hydraulic Testing and Circuit References

Main pump coverage includes delivery and load-sense pressure adjustment. Steering orbitrol valve sectional views support internal service, while TOC8 input/output assignments, fault indications, and programming information explain the electronic side of hydraulic control.

Circuit references include electrical wiring diagrams, the Steering System Schematic, Body System Schematic, Brake System Schematic, transmission Oil Circulation Diagram, and Diagnostic Pressure Check Points drawings. Component-specific and standard bolt and nut torque tables supplement the assembly sections.

The welding procedures identify precautions against damage to electronic controllers. Steering-cylinder assembly notes also address rod-seal damage at threaded surfaces.

Articulation joints, raised bodies, heavy components, and charged hydraulic circuits require the support, lifting, and pressure-release precautions described in the manual.

Examples from Powertrain and Steering Specifications

These entries are a small selection of the technical data provided alongside the service procedures.

Powertrain: TA30 engine data lists maximum torque of 1,775 Nm (1,309 lbf ft) at 1,400 rpm. The three model specification tables list an axle differential ratio of 3.875:1 and a transmission capacity of 63 liters (16.6 US gal), including the cooler.

Steering-cylinder mounting: The articulation and oscillation pivot section specifies 73 Nm (54 lbf ft) for the steering cylinder pin bolts.

PDF Search, Bookmarks and Diagram Detail

Search and readability: Main text is searchable, but some embedded schematic labels are not. Bookmarks open the main manual and four training documents. Dense wiring labels need zooming; small labels in the hydraulic training overview (PDF p. 507) remain pixelated and partly difficult to read when enlarged.

One printable 770-page PDF combines the 436-page maintenance manual, 68-page Cummins Quantum Controls training document, 114-page Hydraulic System training document, 107-page ZF Transmission Controls training document, and 45-page Specifications & Operator Controls training document. Covers, introductory material, contents pages, and 30 blank or intentionally blank pages are already included in these totals.