57.0004.2200 TX5519 - Kit - Installation PDF

OPERATOR HANDBOOK
Code 57.0004.2200 - 03/2004
Assembly kits for handler accessories

TX55-19
English
Edition
CAUTION: THOROUGHLY READ AND UNDERSTAND THIS HANDBOOK BEFORE OPERATING THE MACHINE
CAUTION: KEEP THIS HANDBOOK IN THE MACHINE AT ALL TIMES
ZONA INDUSTRIALE I-06019 UMBERTIDE (PG) - ITALIA
Tel. +39 075 941811 - Fax +39 075 9415382
Technical Assistance Service

Tel. +39 075 9418125
e-mail: im.service@terexlift.it
DEALER’S OR ASSISTANCE CENTRE STAMP
Instructions for Assembly - Use and Maintenance - TELELIFT TX55-19 accessory parts kits
Code: 57.0004.2200
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted
in any form or by any means without prior written permission from TEREXLIFT srl.
In pursuing a policy of constant quality improvement, TEREXLIFT srl reserves the right to make changes at
any time and without undertaking to give prior notice; therefore, also this publication may be subject to
modifications.
Some photos or drawings have been used to illustrate a specific function; as a result, they may not refer to
the machine treated in this manual.
© Copyright 2004 TEREXLIFT srl - All rights reserved
Produced by:
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Handler with telescopic boom TX55-19
Instructions for Assembly - Use and Maintenance
ACCESSORY PARTS KIT
Section A
GENERAL INFORMATION
TABLE OF CONTENTS
A-1 Introduction ................................................................................................................ 6

A-1.1 Symbols ...................................................................................................................... 6
A-1.2 Repair tools required .................................................................................................. 7
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 A-1 INTRODUCTION
CAUTION
This manual is arranged to give you a good Draws the attention either to situations that involve
understanding of the main units of the machine and your own as well as the others’ safety and that
their safe routine and extraordinary maintenance. can result in minor or moderate injury or to
situations that involve the machine efficiency.
STRICTLY COMPLY WITH THE INSTRUCTIONS
IN THIS HANDBOOK!
READ AND UNDERSTAND THIS HANDBOOK IMPORTANT
BEFORE PERFORMING ANY MAINTENANCE Draws the attention to important technical
OR REPAIR. information or practical advice that allows for a
safer and more efficient use of the machine.
If you are unsure about anything, please address
to the TEREXLIFT Technical Service or to your
agent/dealer: addresses, phone and fax numbers RESPECT THE ENVIRONMENT
are printed in the cover and in the title-page of this
Draws the attention to important environment-
manual.
related information.
Keep this manual in the repair shop at all times and
read it before performing any extraordinary
maintenance job. Indicates the number of persons
required for performing the job
 A-1.1 SYMBOLS
In this manual, SPECIAL SYMBOLS are used to point
out important notices, as well as any technical Indicates the time required for
information regarding the tools to be used, the performing the job
recommended tightening torques, etc.
This manual uses five symbols, always combined with
signal words and intended to alert the reader to the
existence and relative degree of a hazard. Indicates the tools required for
Symbols are always followed by a text explaining the performing the job
situation which may be encountered, the attention
which must be paid to and the possible ways of dealing
with these conditions. The text can also be used to
point out prohibitions or to provide instructions for Indicates the weight of the unit to be
eliminating risks. handled
Sometimes, the text can be followed by illustrations.
The symbols used in this manual are the following:

Indicates the recommended tightening
DANGER torque
Draws the attention to situations that involve your

own as well as the others’ safety and that can result
in death or serious injury. Alerts you that an inspection is needed
ELECTRICAL DANGER
Draws the attention to electrical risks that involve
your own as well as the others’ safety and that can
result in death or serious injury.
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 A-1.2 REPAIR TOOLS REQUIRED • 1/4" gas female plug

• 3/8" gas female plug
• 1/2" gas female plug
IMPORTANT • 1" gas female plug
The list below indicates some of the tools required • 1" 1/4 gas female plug
for servicing the machine at best. • 1" 1/2 gas female plug
Basic tools Sealing material

• 6 to 41 mm box wrench set • Teflon tape
• 6 to 41 mm socket wrench set • Loctite sealant
• 2 to 10 mm Allen wrench set • Loctite threadlocker
• External circlip pliers - ø 1060 mm
• Internal circlip pliers - ø 20200 mm Equipment and instrumentation
• Two-leg pullers - ø 25200 mm • Measure instruments: metre, gauge, micrometers
• Three-leg pullers - ø 50400 mm • Compressor with compressed air system
• American cutters • Painting system
• Scissors • Forklift and/or pallet lift
• Screwdriver set • Stackable wooden planks and/or pallets
• Hammer set • Electric welding machine
• M6 to M20 screw-taps and screw die set • Cylinder and blowpipe
• Mallets with plastic plugs • Hoisting means with 5000 kg payload
• Combination pliers • Textile bridles
• Wire nippers • Two-/three-leg chains with hooks
• Nylon collar pliers • Pneumatic screwdriver
• Wire cutter • Water level
• Wire strippers • Bench drilling machine
• Shears • Portable electric drill
• Cutting nippers • Set of helical bits
• Hand-saw • Battery charger
• Cutter • Adjustable stands H = 3001000 mm with 2 to 5
• Slotted screw driver set - ø 2.5  10 mm ton bearing capacity
• Crosshead screw driver set - ø 2.5  10 mm
• Adjustable self-locking pliers Consumables
• Ring nut spanner • Oils
• Wrench set for hydraulic cylinders • Greases
• Drift bolt set • Rags for cleaning
• Chisel set • Gas R134
• Punch
• Funnel Personal protection equipment
• Funnel with flexible extension • Goggles
• Graduated container • Gloves
• Crowbar • Ear-protectors
• Fluid collecting containers • Shoes
• Overall
CSpecial spanner for wheel bolts
• 33mm socket spanner
Fittings for plugging disconnected pipes

• 1/4" gas male plug
• 1" gas male plug
• 1" 1/4 gas male plug
• 1" 1/2 gas male plug
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Section B
SAFETY
TABLE OF CONTENTS
B-1 GENERAL REMARKS ................................................................................................. 10

B-2 PERSONNEL’S REQUISITES ..................................................................................... 10
B-2.1 Qualities required for the operator ............................................................................. 10
B-2.2 Personal protective equipment .................................................................................. 11
B-3 SAFETY INSTRUCTIONS ........................................................................................... 11
B-3.1 Working area .............................................................................................................. 11
B-3.2 During work ................................................................................................................ 11
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B-1 GENERAL REMARKS B-2 PERSONNEL’S REQUISITES
Most accidents which may occur when working,  B-2.1 QUALITIES REQUIRED FOR THE
servicing or servicing public works vehicles, are caused OPERATOR
by not complying with the basic safety precautions. The operators who use the machine regularly or
Therefore, it is necessary to pay steady attention to occasionally (ex. for transport reasons) must have the
the potential hazards and the effects that may come following qualities:
of operations carried out on the machine. health:
before and during any operation, operators shall never
IMPORTANT take alcoholic beverages, medicines or other
substances that may alter their psycho-physical
If you recognise hazardous situations, you can
conditions and, consequently, their working abilities.
prevent accidents!
physical:
good eyesight, acute hearing, good co-ordination and
For instance, this handbook makes use of special
ability to carry out all required operations in a safe way,
safety symbols to alert you to the existence and
according to the instructions of this manual.
relative degree of a hazard.
mental:
CAUTION ability to understand and apply the rules, regulations
and safety precautions. They shall be careful and
The instructions given in this handbook are the
sensible for their own as well as for the others’ safety
ones envisaged by TEREXLIFT. They do not exclude
and shall desire to carry out the work correctly and in
other safe and most convenient ways for the
a responsible way.
machine operation and maintenance that take into
emotional:
account the available spaces and means.
they shall keep calm and always be able to evaluate
their own physical and mental conditions.
If you decide to follow instructions other than those
training:
given in this manual, you must:
they shall read and familiarise with this handbook, its
• be sure that the operations you are going to carry
enclosed graphs and diagrams, the identification and
out are not explicitly forbidden;
hazard warning plates. They shall be skilled and trained
• be sure that the methods are safe and in
about the machine use.
compliance with the indications given in this
section;
IMPORTANT
• be sure that the methods cannot damage the
machine directly or indirectly or make it unsafe; The operator shall have a licence (or a driving
• contact TEREXLIFT Assistance Service for any licence) when provided for by the laws enforced in
suggestion and the necessary written permission. the country where the machine works. Please, ask
the competent bodies. In Italy the operator must
IMPORTANT be at least 18 year old.
Do not hesitate to pose questions if you are in
doubt! Contact TEREXLIFT: their technical service
is at your disposal. Addresses, phone and fax
numbers are given in the cover and in the title-page
of this manual.
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 B-2.1 PERSONAL PROTECTIVE EQUIPMENT • When carrying out operations at hazardous heights
During work, but especially when maintaining or (above 3 meters from the ground), always use
repairing the machine, operators must wear suitable type-approved safety belts or fall protection
clothes and a personal protective equipment: devices.
• Do not enter/leave the machine when it is running.
• Overalls or any other comfortable garments. • Before servicing the engine, let its parts cool down.
Operators should wear neither clothes with large • Do not leave the driving place when the machine
sleeves nor objects that can get stuck in moving is running.
parts of the machine. • Neither stop nor carry out jobs under or between
• Protective helmet when working near suspended the machine wheels when the engine is running.
loads. When a maintenance in this area is needed, stop
the engine, engage the parking brake and chock
• Protective gloves. the wheels to prevent accidental movements
• Working shoes. • Do not carry out maintenance or repair jobs without
a sufficient lighting.
• Breathing set (or dust mask).
• When using the machine lights, the beam should
• Ear-protectors or equivalent equipment. be oriented in order not to blind the personnel at
work.
• Goggles or facial masks.
• Before powering up electric cables or parts, ensure
they are properly connected and in efficient working
IMPORTANT order.
• Do not carry out interventions on electric
Use working clothes and personal protective
components with voltage over 48V.
equipment in good condition.
• Do not connect wet plugs or sockets.
• Signs and stickers shall never be removed, hidden
B-3 SAFETY INSTRUCTIONS or become unreadable.
• Except for maintenance purposes, do not remove
safety devices, covers, guards,. Should their
DANGER removal be necessary, stop the engine, remove
Read and understand the following safety them with the greatest care and always remember
instructions before servicing the machine. to refit them before starting the engine and using
The following list provides important safety the machine again.
instructions which must absolutely be obeyed to • Always stop the engine and disconnect the
prevent accidents and injuries. batteries before servicing or repairing the machine.
• Do not lubricate, clean or adjust moving parts.
 B-3.1 WORKING AREA • Do not do jobs by hand when specific tools are
• Make sure the area all around the machine is safe. provided for this purpose.
Always be aware of potential risks. • Absolutely avoid to use tools in bad conditions or
• During work, keep the working area in order. Never in an improper way.
leave objects scattered: they could hinder the • Before carrying out operations on hydraulic lines
machine movements and represent a danger for under pressure (hydraulic oil, compressed air) or
personnel. disconnecting hydraulic components, ensure the
relevant line has been previously depressurised and
 B-3.2 DURING WORK does not contain any hot fluid.
• Do not walk or stop under raised loads or machine
parts supported by hydraulic cylinders or ropes
only.
• Keep the machine handholds and access steps
always clean from oil, grease or dirt to eliminate
any slippery areas.
• When entering/leaving the cab or other raised
parts, always face the machine; never turn the
back.
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DANGER
Any intervention on the hydraulic or pneumatic
circuit must be carried out by authorised personnel.
Before servicing a line at high pressure, eliminate
any residual pressure from the circuit.
Do not use your fingers to check for pressure leaks.
Fine jets of air, oil or fuel can injure you.
• Do not smoke and do not use open flames if there

is a risk of fire or close to fuel, oil or batteries.
• Do not leave fuel cans or bottles in unsuitable
places.
• Do not empty catalytic mufflers or other vessels
containing burning materials without taking the
necessary precautions.
• Handle all flammable or dangerous substances
cautiously.
• After any maintenance or repair work, make sure
that no tool, cloth or other object has been left
within compartments with moving parts or in which
suction and cooling air circulates.
• Never give orders to more people at a time.
Instructions and signals must be given by one
person only.
• Always pay the due attention to the instructions
given by the foreman.
• Never distract the operator during working phases
or crucial manoeuvres.
• Do not call an operator suddenly, if unnecessary.
• Do not frighten an operator or throw objects by no
means.
• After work, never leave the machine under
potentially dangerous conditions.
IMPORTANT - RESPECT THE ENVIRONMENT

Treatment and disposal of used oils is subject to
federal, national and local laws and regulations.
Dispose of these hazardous and polluting
substances through licensed waste disposal
contractors.
• Use the assistance of a second person to handle

loads weighing 30 to 50 kg.
• For loads heavier than 50 kg, use of hoisting
equipment and slinging devices in accordance with
any national regulations.
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ACCESSORY PARTS KIT
Section C
ASSEMBLING THE MACHINE PARTS

TABLE OF CONTENTS
C-1 WINDOWS AND DOORS KIT ..................................................................................... 14

C-2 WORK LIGHTS KIT ..................................................................................................... 21
C-3 BEACON KIT .............................................................................................................. 26
C-4 HEATER KIT ............................................................................................................... 28
C-5 A/C UNIT KIT .............................................................................................................. 38
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ASSEMBLING THE PARTS 1 Plain washer ø 8x24 UNI 6593

1 Self-locking nut UNI 7474
1 Rubber element ø 37xh5xd10
2 Rubber shock-absorber
WINDOWS AND DOORS 1 Hexagon socket cap screw M5x90 UNI
5931
KIT 2 Straight fitting for hose
Code: 58.2503.6000 1 Water hose, black ø 4/6 l=3500
1 Windscreen c/w wiper
1 Electrical wiper kit
Shipping size: 1 Rubber hose-ring ø 14/18
1 Through rubber element ø 10xh8xd7 for
N Size mm (axbxh) weight kg
spraying nozzle
1 1390x620x1030
Total weight 83
Box contents:
N Item
1 Upper door preassembly
1 Lower door preassembly
1 Seal profile l=4300
1 Side window preassembly - left side
1 Rear window preassembly
1 Side window preassembly - right side
6 Hinge pin  PACKAGING
4 Nylon bushing ø12 x 8,2 h 8,6
4 Nylon hinge h=22
The kit comes pre-assembled into a strong,
8 Screw M6x20 UNI 7687
2 Belt fixing plate
practical cardboard crate for an easy assembly.
1 Door latching belt The packaging is used to protect the product
2 Plug socket during shipping and crates can be stacked one
10 Narrow glass catch on the top of the other up to three.
10 Screw M4.8x38 At the delivery, check that goods have not been
2 Rubber element ø 37x8 h12 damaged during shipping and that all ordered
2 Rubber element ø 37x14 h5 items have been delivered.
2 Nylon countersunk washer ø 37x8 If items have been damaged, immediately contact
2 Screw M8x40 UNI 5933 the dealer or the TEREXLIFT - Shipping dept.
1 Handle stop mod. ‘90
1 Complete lock stop
1 Water tank IMPORTANT
Dispose of the packages in accordance with
1 Water tank support
6 Screw M6x20 UNI 5739 any local regulations. Wood can be burned.
1 Door spring catch Nylon can neither be burned nor be dispersed
6 Serrated lock washer ø 6 UNI 6798 in the environment.
6 Plain washer ø 6x18 UNI 6593
3 Screw M6x25 UNI 5739 DANGER
3 Self-locking nut M8 Wood and nails can injure you! Use protective
6 Plain washer ø 6x12 gloves.
1 Rubber knob for lock
1 Round foam rubber strip ø 50x15 h5
1 Cylindrical vibration-proof element ø
40xh20
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 ASSEMBLING THE WINDOWS KIT
 Windscreen
• Dismantle the protection guards from the

standard cab.
• Raise the boom of the handler and secure it
with rigid struts or keep it raised with an
overhead crane.
• Remove the side cover .

• Drive out the two screws to fix the handle
stop of the windscreen.

• Assemble the windscreen . Fit the
windscreen into the top guide and lock it in
the bottom stop with the relevant handle.
• Remove the plastic cap and reach the

cable-ring; let the wiper wires pass through
and connect them to the electrical connector.
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 Wiper water tank

• Before assembling the wiper water tank ,
remove cap from the plastic cover. Secure
the tank to the bracket with the screws
provided.
• Use the rubber hose to connect the water

tank to the spray nozzle
placed inside the
box of the wiper motor and clamp it with
the two plastic ties provided.
• Proceed with the installation of the water

pump switch of wiper . Remove the
protection cap, pull out the electrical
connector feeding the pump and plug it into
the contact of switch . Fit the wired switch
into its seat.
• Remove the side cover .
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 Assembling the right side window
• Mount the right side window (supplied

complete with gaskets) placing the rubber
washer ø 37 H= 12 between the window and
the upright. Fix the window with the special
blocks along the four sides; fix the window
to the central upright with the rubber element
and the nylon washer .

12
12
 Assembling the left side window 5
• Before assembling the window, drill the fixing

holes as indicated in the drawing to the side.
ø 4,25
68
WARNING
ø 4,00
The holes used to fix the window shall be not Tap M5
be drilled through the entire cab profile. Drill
only the plate.
ø 4,25
12
ø 4,25
100
12
12
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• Mount the left side window (supplied

complete with gaskets) and fix it to the four
sides with the special blocks and the
relevant self-tapping screws.
• Fit the stop to the right block at the top.

This stop will be used when the upper door is
latched in the open position.
 Assembling the door spring catch
• Mount the door spring catch using the 3

screws and relevant washers and nuts. Do
not tighten the screws.
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 Assembling the door
Mount the door as follows:
• Insert the four male hinges into the drilled

holes on the upright and fix it with the M6x20
screws provided.
• Mount the two upper and lower doors (already

preassembled) onto the hinges and fix them
with pins .
• Check if the upper door latches onto the door

spring catch, previously mounted. If the door
latches correctly, tighten the three screws.
• Mount the stop of lock and check that the

lock is in efficient working order before
tightening the stop in position.
• Ensure the upper door latches onto the lower

door.
• Mount the belt of the door catch fixing it to

the upright and the lower door with the special
plates, screws and washers provided.
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 Assembling the rear window
• Fit the bushings provided into hinges

• Install the rear window (already
preassembled) onto the male hinges on the
rear side of the cab.
• Fix the two receptacles supplied to the

crosspiece.
• Mount and fix the two toggles to the
receptacles on the crosspiece and to the cab
window using the fixing screws and .

After the assembly, remove the struts and lower
the boom to the ground.
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ASSEMBLING THE PARTS  PACKAGING

WORK LIGHTS KIT practical cardboard crate for an easy assembly.
The packaging is used to protect the product
Code: 58.2503.0000 during shipping and crates can be stacked one
on the top of the other up to three.
Shipping size: At the delivery, check that goods have not been
damaged during shipping and that all ordered
N Size mm (axbxh) weight kg items have been delivered.
1 290x265x220 7 If items have been damaged, immediately contact
the dealer or the TEREXLIFT - Shipping dept.
IMPORTANT
Box contents: Dispose of the packages in accordance with
any local regulations. Wood can be burned.
N Items Nylon can neither be burned nor be dispersed
1 Work lights kit in the environment.
1 Relay
2 On-off switch
2 Button DANGER
1 Front light with wiring harness Wood and nails can injure you! Use protective
1 Rear light gloves.
1 Front work light bracket
3 Screw M 8x25 UNI 5739
1 Screw M 8x20 UNI 5739
1 Washer ø 8 UNI 6592
3 Spring washer ø 8
4 Washer ø 8 UNI 6593
1 Self-locking nut M 8 UNI 7473
1 Cable tie S16 D16 ø 8.4
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 ASSEMBLING THE WORK LIGHTS KIT
 Front light on the first telescope
The boom has no fixing holes for securing the
mm
light bracket. For the assembly, proceed as
About 50
follows:
• Place the light bracket onto the boom, about

50 mm below the existing holes.
50
• Mark the position of the two fixing holes to
be drilled on the boom.
• Drill the two holes with a helical bit ø 6.5 and
tap M8.
WARNING
Be very careful while drilling in order not to
damage the plate of the telescope.
• Fit the light bracket and lock in position with

two screws M8x25, two flat washers and two
spring washers.
• Place the wired light onto the bracket and lock
in position with screw M8x25, two flat
washers and a self-locking nut.
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 Connecting the front light

• Lay the wire along the boom and secure it to
the iron pipes of the hydraulic circuit with
some ties.
• Connect the wires to the electrical connection
located close to the fuel tank.
• Open the fuse and relay box and insert the

supplied relay in position K1
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 Rear work light
• Secure the rear work light to the existing

bracket on the cab using one screw M8x20,
one flat washer and one spring washer ().
 Connecting the rear light

• The wires of the work light can be connected
to connectors of the cab line.
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 Connecting the switches • Connect the relevant connector to the on-

off switches before refitting the switch boxes.
• Lift out the right and left switch boxes located
on the driving column.
WARNING
• Lift out the protective caps and fit the on-off
switches and supplied. Switch turns on/off the rear light; switch turns
on/off the front work light on the boom.
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ASSEMBLING THE PARTS

BEACON KIT
Code: 56.0010.0005
Shipping size:
N Size mm (axbxh) weight kg
1 145x145x260 0.6
Box contents:
N Items  Beacon
• The machine is already prepared for the
1 Beacon with wiring harness
beacon assembly. All you have to do is
mounting the beacon onto support and
tighten the wing nut to lock it in position.
The beacon will switch on every time the
machine is started.
 PACKAGING

practical cardboard crate for an easy assembly.
during shipping and crates can be stacked one
At the delivery, check that goods have not been
items have been delivered.
If items have been damaged, immediately contact
IMPORTANT

Nylon can neither be burned nor be dispersed
in the environment.

DANGER
Wood and nails can injure you! Use protective
gloves.
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HEATER KIT practical cardboard crate for an easy assembly.
Shipping size: damaged during shipping and that all ordered
items have been delivered.
N Size mm (axbxh) weight kg If items have been damaged, immediately contact
1 670x410x270 12 the dealer or the TEREXLIFT - Shipping dept.
Box contents: IMPORTANT

N Items
1 Heater pre-assembly kit
Nylon can neither be burned nor be dispersed
1 Adjustment cock
4 Metal clamp ø 12/18
in the environment.
1 Paper filter with gasket
1 Adhesive “Aerstop” 3x15mm L= 1000 DANGER
1 Air filter gate Wood and nails can injure you! Use protective
2 Male knob ø 6x15 gloves.
2 Air flaps
1 Wiring harness
1 Fan pushbutton
2 Male fitting for Deutz motor
2 90 female fitting
2 Hose fitting
2 Copper washer
2 Copper washer
5 Legrand tie 2,5x125
5 Legrand tie 9x265
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 ASSEMBLING THE HEATER KIT
• Raise the boom of the lift and secure it with

rigid struts or keep it raised with an overhead
crane.
• Remove the side cover from cab and the

protection cover of system

• Raise the engine cover, place a container
underneath the engine to collect any spilled
oil and replace the two plugs with fittings
for the heater circuit.
• Remove cover and store the fixing screws

away.
• Remove the closing cap near the housing of

the adjustment cock

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• Remove the cup nd prise off the closing

cap.
• Install the rocker pushbutton for the

selection of the fan speed.
• Remove the 5 screws fixing the plastic cover

and proceed with the electrical
connections.
• Remove the adjustment cap pressed into

cock
, as well as nut
• Install the cock on the plastic cover and

tighten it with the nut previously removed
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• For the electrical connection, remove the fuse

box cover or the plastic cover .
• Using a cutter, cut the external protection

covering the slots under the seat for the
passage of the heater tubes, the cables and
the filter air intake.
• Lay the cables from the fuse box to the heater

housing under the driving seat passing
through the slot located in the front, on the
right, and bring the cables out of the cab.

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• Fix the ground terminal under the fixing screw

of horn
• Plug the connector of the rocker pushbutton

for the selection of fan speed .
• Remove the 4 screws fixing the fuse and relay

holding plate (using a 4mm hexagonal
screw and a crosshead screwdriver) and
connect the pink cable to the free connection
under the 10A fuse F2.
• Fix the cables with the plastic ties provided.
F2
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ACCESSORY PARTS KIT

A
B
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ACCESSORY PARTS KIT
Rest the preassembled heater unit on the cab

floor and connect as follows:
• Cut the lower hose from the heater to a
length of 1100 mm.

• Let the tubes pass through the two holes

previously set free.
• Connect the short hose to the cock

previously installed.

• Connect the length of hose previously cut
to the second hose fitting on the cock; tighten
the hoses to the fittings with the metal hose-
clamps provided.
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• Let the two hoses and pass through hole

on the frame and connect them to the
fittings previously installed on the engine.
Cut the excess hose and fix with the metal
clamps provided.

• Connect the electrical connector on the

heater to the line already prepared on the
machine.
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• Place the heater under the driving seat with

caution paying attention not to bend or
damage the rubber hoses. Lock the cover in
position with the original screws.

• Install the air filter with the gasket pointing
toward the cab wall.
• Mount the protection of the air filter and fix it

with the two threaded knobs provided.

• Press in the two air flaps provided.
• Once the heater has been assembled, refit all

the parts that have been removed, say: plastic
cover to the right side of the cab, fuse box
cover, metal side cover and hydraulic system
protection cover.
Make sure that no tools or rags have been
left near moving parts (for instance, close to
the engine fan).
• Start the engine and check the heating system

is in efficient working order.
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USE OF THE HEATER
Heated air
• Turn the heated air cock

counter-clockwise
so the air heating fluid starts circulating.
The amount of heated air will be proportional
to the opening of the relevant regulator.
• Adjust the heated air operating the rocker

switch to select one of the two available
speeds.
• Open the air flaps and adjust their position to

direct the air as you want.
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ACCESSORY PARTS KIT

A/C UNIT KIT practical cardboard crate for an easy assembly.
Only for handlers mod. TX 55-19 on the top of the other up to three.
Shipping size: items have been delivered.
N Size mm (axbxh) weight kg If items have been damaged, immediately contact
1 610x440x300 12
1 610x440x300 17
Total weight 29 IMPORTANT
Box contents: Nylon can neither be burned nor be dispersed
in the environment.
N Items
1 Evaporator preassembled unit
1 Radiator condenser preassembled unit
DANGER
1 Compressor bracket
Wood and nails can injure you! Use protective
1 Compressor
1 Belt tightening bracket gloves.
1 Belt AV13x850
4 Flexible hose with fittings
2 Hose fixing bracket
1 Wiring harness
1 4-pole connector
1 30A fuse
10 Legrand tie 2,5x125
10 Legrand tie 9x265
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ACCESSORY PARTS KIT
 ASSEMBLING THE A/C SYSTEM KIT
• Raise the boom of the lift and secure it with

rigid struts or keep it raised with an overhead
crane.
• Remove the side cover from cab and the

protection cover of system

• Lift up the engine cover and hold it in the

raised position.
• Place a lift truck under the engine base to
support the engine.
• Remove 4 of the 5 screws fixing the engine

base to the frame (leave in place only the
rear screw).
• Lower the lift truck supporting the engine base
to gain access to the auxiliary circuit pump
.
CAUTION
If the engine base does not lower enough to reach
the pump, remove the clamps from the exhaust
manifold.
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ACCESSORY PARTS KIT

• Dismantle pump by removing the two fixing

screws without disconnecting the flexible
hoses.
CAUTION
Once the screws have been removed, lift out
the supporting plate from the centring pins
to free the pump completely.
We recommend prising this plate off with a
lever.
• Mount the compressor drive belt passing it

on the free race of pulley . Reassemble
pump .
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ACCESSORY PARTS KIT
• Preassemble the supporting bracket , the

compressor and the belt tightening bracket

using 2 M8x20 screws and spring washers
and 2 M8x25 screws and plain washer ø8x24
and spring washer.
• Mount the preassembled unit onto the engine

using 2 M14x50 screws and plain washers

ø14x28 and spring washers.
• Check the pulleys are aligned and tighten the
screws.
• Connect the drive belt and tension using a

lever, then tighten the screw of register
.
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ACCESSORY PARTS KIT
• Install the radiator (already preassembled)

on the engine heat exchanger using the two
holes to fix it in position with 2 M6x20
screws and plain and spring washers.
• Drill ø5 and tap M6 the two holes on the

engine exchanger to fix it to the internal side.
CAUTION
Be very careful while drilling so as not to pierce
the hoses of the exchanger located in the
opposite side.
• Fix the radiator of the A/C unit with 2 M6x20

screws and plain and spring washers.
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ACCESSORY PARTS KIT
• Connect the parts with the hoses provided

according to the following scheme:

A/C unit compressor
A/C unit heat exchanger
thermal engine heat exchanger
filter
• Clamp the flexible hoses to the compressor
with 2 M6x20 screws and plain washer.
IMPORTANT
Let the hoses from/to the evaporator pass
through hole on the frame side.

EVAPORATOR
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• Remove heater located under the driving

seat and store the relevant screws as they
will be used to fix the evaporator.
• Disconnect the rubber hoses of the heater

being very careful not to spill any oil.
• Disconnect the electrical connector to free the

heater.

• Place the evaporator onto the cab floor and
proceed with the connections.
• Replace the original 3-pole connector with

the 4-pole connector supplied respecting the
following order:
Wire on Wire on
system evaporator Function
black black ground
red/blue red 3rd speed
white/black blue 2nd speed
blue (see note) orange 1st speed

NOTE
The blue wire of the system is part of electrical
wiring of line
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ACCESSORY PARTS KIT
• For the electrical connection, remove the fuse

box cover or the plastic cover .
• Drill ø20 on the plastic cover as shown to

install the compressor on-off pushbutton.
ø 20
40

• Remove the 5 screws fixing the plastic cover
and proceed with the electrical
connections.
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ACCESSORY PARTS KIT
• Connect the cables supplied from the fuse

box to the compressor, the filter, the
compressor on-off button and the evaporator.
• Clamp the cables with the plastic ties

provided.
• Fix the relay unit to the side of the fuse board

with the 2,5x125 plastic ties.
• Proceed with the connection as follows:

- connector to the 5A fuse F15
- connector to the 10A fuse F13
- terminal clamp to ground in the horn
fixing screw
- terminal clamp to the free seat of the
new 4-pole connector previously installed
in the feeding line of the evaporator fan
- connector to the compressor letting
the cable pass through hole on the
frame
- connector to the fan thermostat
- terminal clamp to the filter pressure
switch
- Mount the on-off button of compressor
into the hole previously drilled on the
plastic cover.
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ACCESSORY PARTS KIT
• With the evaporator/heater unit on the cab

floor, make the following connections:
- Connect the two hoses, previously

disconnected from the heater, to the hose
fittings on evaporator . Reversing the
assembly order doesn’t cause any
problems. Fix the hoses with the metal
clamps ø12/18 supplied.
- Connect the two hoses from the

compressor and filter
to the special
fitting on the evaporator. Fix the hoses with
the plate and the M6x20 cylindrical screw
+ plain and spring washers. In this case the
assembling order is univocal as the hoses
have different diameters.
- Insert the water drain hose into the

special hole to drain the condensed water
off.

• Since the evaporator housing is quite small,
place the unit with caution and pay attention
that hoses are not strangled or damaged
during installation.
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• Replace the 5A fuse F15 (ref. ) with the 30A

fuse supplied.

• Check that all cables have been clamped with

the plastic ties provided before refitting the
protection cover.
• Replace the engine base and refit the side

cover of the cab and the system protection
cover.
• Fill the circuit of the A/C unit through the

special fitting of the compressor tube with
gas HFC R134.
• Test the A/C system is in efficient working

order.
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ACCESSORY PARTS KIT
USE OF THE A/C UNIT

Heated air
• Turn the heated air regulator counter-
clockwise so the air heating fluid starts
circulating.
The amount of heated air will be proportional
to the opening of the relevant regulator.

• Adjust the heated air operating switch to

select one of the three available speeds.
• Open the air flaps and adjust their position to

Unheated air
• Make sure the regulator is turned clockwise
to limit stop in the closed position.
• Press button and start the compressor.
• Adjust the unheated air operating switch

to select one of the three available speeds.
• Open the air flaps and adjust the position to

CAUTION
A wrong regulation of the A/C unit may cause
discomfort. Be very careful to temperature
changes between the cab and exterior.
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ACCESSORY PARTS KIT
MAINTENANCE SCHEDULE
• Every 50 hours check that the air filter is

clean. If the filter has to be cleaned, pull out
the relevant cartridge and dry-clean it.
• Every 50 hours check that the radiator is

clean. If the radiator has to be cleaned, direct
a jet of compressed air toward the cooling
core.
• Every 250 hours check the tension of the

compressor driving belt . If the belt has to
be re-adjusted, operate the register
.

• Before the hot season begins, have the A/C
unit checked and, in case, refilled by a
specialised technician.
Page 50
Document 57.0004.2200 - 03/2004

57.0004.2200 TX5519 - Kit - Installation PDF

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OPERATOR HANDBOOK

Code 57.0004.2200 - 03/2004

Assembly kits for handler accessories

Technical Assistance Service

DEALER’S OR ASSISTANCE CENTRE STAMP

© Copyright 2004 TEREXLIFT srl - All rights reserved

A-1 Introduction ................................................................................................................ 6

The symbols used in this manual are the following:

Draws the attention to situations that involve your

 A-1.2 REPAIR TOOLS REQUIRED • 1/4" gas female plug

Basic tools Sealing material

Fittings for plugging disconnected pipes

Page left intentionally blank

B-1 GENERAL REMARKS ................................................................................................. 10

B-1 GENERAL REMARKS B-2 PERSONNEL’S REQUISITES

• Do not smoke and do not use open flames if there

IMPORTANT - RESPECT THE ENVIRONMENT

• Use the assistance of a second person to handle

ASSEMBLING THE MACHINE PARTS

C-1 WINDOWS AND DOORS KIT ..................................................................................... 14

ASSEMBLING THE PARTS 1 Plain washer ø 8x24 UNI 6593

 ASSEMBLING THE WINDOWS KIT

• Dismantle the protection guards from the

• Remove the plastic cap  and reach the

 Wiper water tank

• Use the rubber hose to connect the water

• Proceed with the installation of the water

• Remove the side cover .

 Assembling the right side window

• Mount the right side window (supplied

• Before assembling the window, drill the fixing

• Mount the left side window  (supplied

• Fit the stop  to the right block at the top.

 Assembling the door spring catch

• Mount the door spring catch  using the 3 

 Assembling the door

Mount the door as follows:

• Insert the four male hinges  into the drilled 

• Mount the two upper and lower doors (already

• Check if the upper door latches onto the door

• Mount the stop of lock  and check that the

• Ensure the upper door latches onto the lower

• Mount the belt of the door catch  fixing it to

 Assembling the rear window

• Fit the bushings provided into hinges

• Fix the two receptacles supplied to the

ASSEMBLING THE PARTS  PACKAGING

The kit comes pre-assembled into a strong,

 ASSEMBLING THE WORK LIGHTS KIT

 Front light on the first telescope

The boom has no fixing holes for securing the

• Place the light bracket onto the boom, about

• Fit the light bracket and lock in position with

 Connecting the front light

• Open the fuse and relay box and insert the

 Rear work light

• Secure the rear work light to the existing

 Connecting the rear light

 Connecting the switches • Connect the relevant connector  to the on-

ASSEMBLING THE PARTS

The kit comes pre-assembled into a strong,

Page left intentionally blank

ASSEMBLING THE PARTS  PACKAGING

• Remove the plastic cap and reach the

• Mount the left side window (supplied

• Fit the stop to the right block at the top.

• Mount the door spring catch using the 3

• Insert the four male hinges into the drilled

• Mount the stop of lock and check that the

• Mount the belt of the door catch fixing it to

 Connecting the switches • Connect the relevant connector to the on-

• Remove the cup nd prise off the closing

• Install the rocker pushbutton for the

• Connect the short hose to the cock

• Let the two hoses and pass through hole

• Connect the electrical connector on the

• Preassemble the supporting bracket , the

• Drill ø5 and tap M6 the two holes on the

• Remove heater located under the driving

• Replace the original 3-pole connector with

• Drill ø20 on the plastic cover as shown to

• Adjust the heated air operating switch to