Terex TR40 TR45 Off-Highway Truck Parts Book 15275764 – Illustrated Parts Catalog PDF (Cummins QSK19-C525, Serial T8171011 to T8171141)

Description

Terex TR40/TR45 Parts Book – Part Number 15275764

This is the illustrated parts catalog published for the TR40 and TR45 off-highway trucks fitted with the Cummins QSK19-C525 Tier 2 engine. It covers the complete machine in exploded-view form, from the main frame rails back to the rear axle planetaries and up into the cab trim. Every assembly page carries an item-numbered drawing paired with a parts list giving the reference number, quantity required, Terex part number and description.

Because Terex built these trucks in discrete serial batches, the book is organised by serial effectivity rather than by a single blanket listing. You will see entries qualified as running “from serial no. T8171011”, or split at a break point such as T8171086, T8171087, T8171137 or T8171138, so the correct part is ordered for the machine in front of you rather than the nearest-looking equivalent. The serial range covered is T8171011 through T8171141.

File Details

• Manual type: Illustrated parts book / parts catalog
• Brand: Terex
• Models: TR40, TR45 off-highway truck
• Engine: Cummins QSK19-C525 Tier 2
• Part number: 15275764
• Publication date: March 2002, revised November 2006
• Language: English
• Page count: 418 pages
• File format: PDF

Chapters Covered

• Section 100 – Chassis
• Section 110 – Engine
• Section 120 – Transmission
• Section 130 – Driveline
• Section 140 – Front Axle
• Section 160 – Rear Axle
• Section 165 – Brake Parts
• Section 180 – Suspension System
• Section 190 – Electrical System
• Section 200 – Fuel System
• Section 210 – Cooling System
• Section 220 – Steering System
• Section 230 – Body System
• Section 250 – Braking System
• Section 260 – Cab
• Section 270 – Body
• Section 290 – Decals
• Section 300 – Miscellaneous

Section 100 – Chassis

The structural heart of the book. Pages cover the complete frame assembly, the transmission guard, the hood and its mounting hardware, fenders and platforms for both the early and later serial splits, ladders and handrails, the radiator guard, and the mudguard set. Fastener callouts are given individually, so bolt, washer, lockwasher and nut part numbers are all listed rather than being lumped into a single hardware line.

Section 110 – Engine and Section 120 – Transmission

The engine section opens with an ordering note stating that Terex does not sell the Cummins engine or its internal parts, and that those items come from Cummins directly. What the book does carry is the installation side: engine mounting, isolation mounts, the fan and damper, belts, the alternator guard, the security kits for the engine oil filler and dipstick, the air cleaner assembly with main and safety elements, and the complete air cleaner pipe and hose routing. It also covers the engine power take-off.

Section 120 is far deeper and is effectively a transmission parts book in its own right. Transmission mounting and the trunnion assembly, the transmission breakdown, the control valve with its long list of valves, springs, solenoids and body assemblies, the shift control with ECM, harnesses and shift selector, the power take-off, the filter assembly, oil lines for both sides of the serial split at T8171086/T8171087, and the retarder control lines. The internal groups are broken out in full: front cover and converter group, converter housing group, oil pump, filter adaptor and regulator valves, lockup valve, retarder group, retarder control valve, splitter gearing and clutches, main housing group, and the high, intermediate, low and reverse range gearing and clutch packs – each with its own drawing page and plate/friction disc listings.

Section 130 – Driveline, 140 – Front Axle, 160 – Rear Axle, 165 – Brake Parts, 180 – Suspension

Front and rear drivelines are shown as complete assemblies with screw, tube assembly and U-joint breakdowns. The front axle section handles the wheel, rim and tyre assembly, including bearings, seals, studs, bead seat band, lockring and the hub cap hardware. The rear axle section is the largest single-axle group in the book: differential assembly with carrier, spider, pinions and gear set, the banjo and spindle assembly with oscillation stops and bushings, rear planetary gearing shown in two versions split at serial T8171060, and the rear drive wheel with its rim components. Brake parts cover the front and rear wheel rigid assemblies, with caliper pistons, seal kits, lining kits, discs and the rear parking and service piston arrangement. Suspension covers the front and rear ride cylinders with their seal kits, wear rings, wipers, piston rods and recharge valves.

Section 190 – Electrical System

A long reference section that starts with terminal charts – spade, ring, pin, socket, bullet, fork, battery cable ring and clamp – listed by nominal size, cable size and part number. It then provides connector charts by terminal type and manufacturer (Rists, Bayonet, AMP, Cannon, Packard, Deutsch, Kostal, Lucas, Hella and others). Beyond the hardware charts, the section includes cab harnesses with full circuit routing sheets, chassis and engine harnesses, battery and cable assemblies, battery mounting, the lighting system, alternator and starter motor, switches and sensors, radio and speakers, and the horn.

Section 200 – Fuel System and 210 – Cooling System

Fuel tank assembly with cap, gauge, strainer and mounting straps, plus the fuel lines with shut-off valve, cooler and filter connections. Cooling covers the radiator assembly in two build versions, radiator mounting and piping, the charge air cooler and its pipework, the remote header tank and hoses, the disc brake oil cooler and its piping, and the transmission oil cooler with hoses and saddle clamps.

Section 220 – Steering System

Steering lines, line filtration, the steering tank and mounting, the steering pump with its rotating group and compensator kit, pump and accumulator mounting, four different accumulator build specifications across the serial range, the steering valve, the double relief valve (early and late versions), and the steering cylinder in both the Terex and Parker variants split at T8171067/T8171068. Steering linkage and column mounting complete the section.

Section 230 – Body System and 250 – Braking System

The hoist system is covered thoroughly: lines and fittings, servo control lines, the hydraulic tank in two distinct builds split at T8171138, the hoist pump, the main hoist control valve, control valve mounting, the joystick, the kick-over valve in early and late versions, kick-over valve mounting, relief valve, pilot supply valve and the hoist cylinders. The braking section runs from the hydraulic brake lines through the brake manifold and PAS valve, the brake accumulator in both the pre-T8171132 and later specifications, treadle valve, directional control valve, monoblock brake valve, retarder control valve and the disc brake filter assembly.

Section 260 – Cab, 270 – Body, 290 – Decals and 300 – Miscellaneous

Cab assembly with glass, wiper system, trim panels, door assemblies for left and right hand sides with handles, locks, hinges and sliding windows, cab mounting, switches and instruments, driver and passenger seats, air conditioner and heater units in early and later versions, heater lines and wiring, air conditioning lines and the windscreen washer. Body section covers the body assembly with hinge pins, shims and cab guards, exhaust heated body in two versions split at T8171051, and rock ejectors. Decals are listed individually by part number for the English set, split at T8171062, plus anti-slip walkway surfaces. Miscellaneous covers multi-tube clamps and hardware.

How the Book Is Organised

Every major section follows a page-code convention: section number, page number and model PLI, for example 220-0120-8171 for the steering cylinder. The table of contents lists each page with its serial effectivity and revision date, so you can confirm at a glance whether a page applies to your truck before you read a single part number. Assembly listings use indented descriptions – an item indented beneath another is a component of that assembly, and ordering the parent gives you the parent with its indented children included. Note letters in the left column flag special ordering or application instructions at the foot of the page, and abbreviations such as N.S.S. (not sold separately) and N.L.A. (no longer available) are used where a component cannot be bought on its own.

What This Parts Book Lets You Do

Ordering the wrong part for a haul truck is an expensive way to lose a shift. This catalog gives you the correct part number for your exact serial number, drawn from the same plate pages the parts counter uses, so you can price a repair, build a stock list, or verify a component before a rebuild rather than after. It supports the full spread of work on these machines: transmission clutch pack and range gearing overhauls, differential and planetary rebuilds, brake caliper and accumulator service, steering cylinder reseals, hoist cylinder work, hydraulic line replacement, cab trim and door hardware, and electrical connector identification when a harness plug has to be matched to a terminal and cable size.

For anyone maintaining a TR40 or TR45, it is also the fastest way to understand how a system is put together before the machine goes into the workshop – which components sit inside the assembly, what seals and bearings go with them, and where the serial break points fall.

IMAGES PREVIEW

Delivered as an instant PDF download after payment, with no shipping and no waiting on a supplier. Open it on a laptop in the workshop office, on a tablet at the machine, or print the pages you need for the job at hand. The full 418-page parts catalog, in English, covering Terex TR40 and TR45 off-highway trucks from serial T8171011 to T8171141.