Owners Manual

TXCR325/A/B
(Model VW7 and 17-9057)

MACHINE MODEL:_____________________
MACHINE SERIAL #:___________________
BLOWER SERIAL #:____________________
HYDRAULIC DRIVE SERIAL #:__________
INSTALL/INSERVICE DATE:_____________

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TXCR325.doc

1/31/2008

APPLICATION
TXCR325 USED ON T/RT500, 600,700
TXCR325A USED ON RT1120
TXCR325B USED ON T/RT200, 300

KENWAY AC SYSTEM
Overview:
The Kenway AC System is a standard automotive thermo-expansion valve system. It
differs in that it is not driven by a gas or diesel engine but is driven by a hydraulic motor.
If the hydraulic motor is functioning correctly any qualified automotive AC technician
should be able to service the AC side of our unit.
Below left is a typical cab unit. It consists of a heat exchanges and a blower with motor.
The heat exchanger is the AC systems evaporator coil. Outside air is filtered by a paper
filter located in the housing on the back of the cab. Inside air is filtered by a reusable
foam filter located on the front bottom of the blower unit.
On the right is the MD 9057 Hydraulic Drive Unit. Its main components are: Hydraulic
drive motor; AC compressor, AC Condenser heat exchanger and the Receiver-Drier.

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Kenway Hydraulic Drive Details [Model 17-9057]:

AC
Compressor
Receiver
Drier

Condenser

Hydraulic
Motor

The Hydraulic Drive Unit has two major components: the hydraulic drive motor; AC
compressor; Hydraulic Oil Heat Pump.
Hydraulic Motor
The AC compressor and pump are belt driven by a hydraulic motor. The motor is
powered by the machines hydraulics. The hydraulic circuit that drives the motor is in
series with the swing valve. Flow comes from the swivel to the Kenway drive unit on to
the swing valve.

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Controls:

Manual
The master power & fan speed selector switch powers up the unit and provides
operator control of three fan speeds.
The mode selector switch allows the operator to set the unit to fan only; AC; or
heat mode (Oil Heat (optional).
The Swing Sense Selector Switch allows the operator to select or deselect Swing
Sense Mode. Swing Sense mode when selected the light on the switch will come
ON. In Swing Sense mode, the unit will disable the AC clutch whenever the
machine is swinging. Note: Continuous swing operation can result is poor AC
system performance.
Warning: Operating the crane with Swing Sense Disabled can result in
fluctuations of swing speed when the AC clutch is activated or inactivated.

Automatic

A Swing Sense Pressure Switch (right) is mounted on the Hydraulic motor near
the outlet port. It senses when the machine is swinging a load. When this occurs,
AC clutch operation is temporarily suspended.
On the AC side, a Thermostat switch (left) located inside the blower unit
prevents evaporator coil freezing up.
The Binary pressure switch (right) is located on the receiver drier out on the
hydraulic drive unit and protects the AC systems from excessively high or low
system pressures.

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Maintenance:
Check

Check/
Inspection
point
Remove
Recirculation
Air filter.

D
a
i
l
y

Remove and
inspect Fresh
Air filter.

A
I
r

H
e
a
t

Observation

Action/Remedy

Clean and damage free

X
X

X
X

Impregnated with dust and dirt

Re-install.
Blow clean with low pressure air
gun or wash with soap and water.

X
X

Worn out or torn.

Replace with new.

Clean and damage free.

Re-install

Impregnated with dust and dirt

Blow clean with low pressure air

gun.

Worn out, un-cleanable or torn.

Replace with new.

Note: If both fresh air and recirculation filters are excessively dirty, check the evaporator and heater
coil for dirt contamination and clean with warm water and soap to get optimum AC and heat
performance.

Check Cab
Blower Motor

TXCR325.doc

Distinctive airflow change for each

speed. No unusual noises from
blowers.

No Action necessary.

Systems doesn't power up.

Check fuses.

No fan speeds.

Check fan resistor.

Excessive noise.

Check blowers for damage.

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Maintenance:
Check

W
e
e
k
l
y

Check/
Inspection
point

Check
Compressor
Or
Heat Pump
Drive Belt

A
I
r

H
e
a
t

Observation

Action/Remedy

Clean, tight, and damage free

No Action necessary.

Loose without wear.

Retighten to 90 lbs. tension. when cold.

Minimum of 50 lbs. when hot.

Oil Slicked/glazed/ or excessively

worn or damaged.

Replace with new. Tension 1/2" belt to

121 lbs., 5/8" to 132 lbs.

AC On, Fan operating, coil free of

dirt and debris. No physical
damage. Good Cooling
AC On. Fan not turning, clutch
cycles off repeatedly. Poor
cooling.

X
Check
condition of
Condenser
Assembly.

Check
condition of AC
and Heater
Hoses

TXCR325.doc

AC On and fan turning slowly.

Poor cooling

Condenser coil clogged with dirt

and debris.

Condenser coil physically

damaged.

No Action necessary.
Troubleshoot electrical circuit. Check
condenser ground, Relay, Fuse.
Fan worn out. Replace.
Clean with air, soap and water, or coil
comb. Do not use sharp tools or bend the
fins.
Have AC system repaired immediately.
Delays will result in more costly repair
later on.

Secure without damage or visible

oil/dirt contamination on unions.

No Action necessary.

Worn or abraded.

If AC hose have serviced. If heater hose

determine cause, rectify problem and
replace hose.

Loose

Re-secure with hose clamps or nylon ties.

Oil/dirt accumulation.

Indicates refrigerant and or oil leak. Have

system promptly serviced.

1/31/2008

Maintenance:
Check

M
o
n
t
h
l
y

Check/
Inspection
point

Air Conditioner
Clutch

A
I
r

H
e
a
t

Oil heat

Air Conditioner
Compressor

TXCR325.doc

No unusual noise. No clutch

slippage: sharp engagement and
release. No oily dirt accumulation
on fittings or seals.
No engagement. AC Mode "On";
No or low voltage.

Troubleshoot electrical circuit. Check

refrigerant pressure.

Clutch slips, Voltage across coil

above 9 V. (22V)

Excessive discharge pressure. Check

condenser fans and coils. Determine
cause and correct.

Clutch slips, Voltage across coil

below 9 V. (22V)

Troubleshoot electrical circuit. Check

compressor ground.

Remove Pressure or temperature

switch and check for poor quality
of oil in heat circuit.

Replace oil and Troubleshoot oil

exchange circuit.

Unusual noise-AC cooling.

Unusual noise-AC not cooling.

No Action necessary.

Check for clutch wear. Turn off machine.

Maximum air gap is: .031". Have clutch or
compressor replaced.

Clutch cycles On and Off rapidly,

Poor cooling,

Check
Receiver Drier
Sight Glass
with machine
operating in
max. AC mode.

Action/Remedy

Clutch slips, Voltage across

clutch coil above 9 V. (22V)

X
X

Observation

Oily dirt accumulating behind

pulley or around compressor
seals.
Sight glass clear. AC Cooling
properly.

Sight glass is milky. AC cooling

properly.

Sight glass has large bubbles or

is milky. AC not cooling properly.

Low ambient temperature move machine

to warm shed and repeat. Low refrigerant
charge-discontinue AC operation until
serviced.
Check compressor mount components for
tightness/ check clutch air gap for
minimum clearance of .016" and
uniformity.
Worn or damaged clutch or compressor.
Discontinue operation until serviced.
Indicates refrigerant and oil leak. Have
system promptly serviced.
No action necessary.
If over 80F, no action necessary. If not
may indicate slightly low charge or
refrigerant contamination. Have serviced
soon.
Probable low refrigerant charge. Service
AC system immediately.

1/31/2008

SERVICE & TROUBLESHOOTING

Electrical Service:
Warning:

Do not wear loose clothing that may get caught in moving parts.
Surfaces maybe slippery! Take care while moving about the machine.
Although when working with 12V the risk of electrocution is low, there is a risk of causing very
expensive damage to machine.

Precaution:
Know your basic electrical circuit.
Always use a multi-meter to check circuit continuity and resistance.

Hydraulic Service:

Warnings:
Surfaces can be Hot!
Be aware of high-pressure discharges.
Always wear safety glasses and protective gloves.
The hydraulic drive unit may also have Air Conditioning components. They should only be
disturbed by a qualified technician.

Precautions:
Do not leave any system open. Always keep all hoses and components capped.
Do not introduce water, dirt or any debris into the system.
See article: Working Safely with Fluid Power by James Weber (contact Kenway Engineering)

AC Service:
Warning:

Direct contact with refrigerant can cause frostbite or blindness.

Always wear safety glasses and protective gloves.
Do not work with refrigerant close to the face.

Do not mistake refrigerants. Check AC system and container labels.

Do not release refrigerant into the air. It is prohibited by federal law.
Do not mix refrigerant oils.

Precaution:

Electrical Service Tools:

List:

Digital Multimeter

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1/31/2008

Multimeter Leads: Pointed and Clamp style

Sewing Pins (Probing wires)
Mini-screwdriver set
Needle nose pliers
Miscellaneous insulated terminals and crimp pliers

Hydraulic Service Tools:

List:

Hydraulic Pressure Gauge (5000 psig) with 1/8 Test Port Coupler (Std on Terex
machines)
Hydraulic Pressure Gauge (160-200 psig) with 1/8 Test Port Coupler
Photo-tachometer and paint marker.
(note: Kenway Kit: 179-TEST KIT contains the above pressure gauge (List Price:
$235))

AC Service Tools:
List:

Manifold gauge set with R-134a quick disconnect (automotive) fittings.

Refrigerant Leak Detector.
Scale: 0-30 lbs minimum range. Readings in .01 lbs increments.
Vacuum Pump.
Thermometer
Refrigerant Recovery Unit.
See ToolSource.com; Cartools.com

Service Tool Tips:

z Always read the tool manual.
z An AC service is only as good as the tools used.
z Well maintained tools will last for many years.

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ELECTRICAL SERVICE AND TROUBLESHOOTING

Tips

Electrical Service and Troubleshooting should occur before mechanical.

With the machine engine Off, check electrical operation of the blower, clutches, etc.
Check that male & female connectors are properly engaged.
Grounding problems can occur over time. Check for corrosion along electrical paths.
Check wire routings for excessive strain and abrasion.
Check for damage to multi-pin connector bodies.
Check for terminal corrosion.
Only use high resistance multimeters when troubleshooting circuit which contain electronic
controllers and circuit boards. Never use a test lamp!

TheElectricalSchematicfollows.

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SCHEMATIC, ELECTRICAL AC ONLY SYSTEM W/ MODEL VW7

BLOWER AND MODEL 9057 HYDRAULIC DRIVE UNIT.
(29-HYD-033)

ITEM
1
2
3
4
5
6
11
16
17

PART #
400093-A
78B-12010
463710-A
461904
403081
122-SD4004
174-PS-010
461146
463509

DESCRIPTION
SWITCH, MASTER PWR & FAN SPEED
BLOWER, W/ 3-SPD RES.
SWITCH, MODE-ROTARY
SWITCH, AC THERMOSTAT-FIXED
SWITCH, AC BINARY PRESSURE
CLUTCH, AC COMPRESSOR
SWITCH, SWING SENSE PRESSURE (NO)
RELAY
SWITCH, LIGHTED ROCKER

END

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Hydraulic Service and Troubleshooting

Prior to any Service work the following should be checked.

Visual Check:

Check for hydraulic oil leaks.

Check hoses for routing problems like kinks or possible abrasion or slicing.
Broken, discolored or disconnected wiring.
Pinched hydraulic lines.
Check tension on drive belt/s.
Check condition of the drive belt: chipped, frayed, cracked

Check the Controls:

Does the cab unit blow air? Check fuse and electrical connections to the controls
and blower system.
The electrical schematic appears on page 11.

Check the Mechanics

Is the drive motor turning?

Is it turning slowly? Normally: 850 to 950 at engine idle
Is it turning in the proper direction? CCW as viewed from back.
Is there an unusual noise coming from the motor?
Is the belt slipping?

AC Service and Basic Troubleshooting

Inspection:
Prior to diagnosing or performing any service, each component should be inspected.
Use the Basic Inspection/Troubleshooting Chart which follows.

If a problem cannot be solved feel free to contact: Kenway Engineering, Inc at 507-2389051 between the hours of 8:00am to 4:30 pm CST. Please have the following
information:
Machine Model, Serial #, and Hour meter reading
Kenway Serial #s from the blower unit and hydraulic drive unit (see the following
breakdowns for serial # location)

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1/31/2008

Maintenance & Basic Troubleshooting:

Check/ Inspection
point

Inspection
Interval

Remove
Recirculating Air
filter.

Daily/
Application
Dependent

Remove and
inspect Fresh Air
filter.

Daily/
Application
Dependent

Observation

Action/Remedy

Clean and damage free

Re-install.
Blow clean with low pressure air gun
or wash with soap and water.
Replace with new.
Re-install
Blow clean with low pressure air
gun.
Replace with new.

Impregnated with dust and dirt

Worn out or torn.
Clean and damage free.
Impregnated with dust and dirt

Check Cab
Controls.

Worn out, un-cleanable or torn.

Note: If both fresh air and recirc. filters are excessively dirty, check the
evaporator coil for dirt contamination and clean with warm water and
soap to get optimum AC performance.
Follow operation instructions at the
beginning of this manual.

Monthly
System powers down and up.

Power Off/ Power

On

Systems doesn't power up or

down.
Distinctive air flow change for
each speed. No unusual noises
from blowers.

Check blower
speeds

No blower operation
No fan speeds.

Check Compressor
Drive Belt

Turn on AC and
check compressor
clutch and
compressor
operation.

Weekly

Monthly

Check fuses.
No Action necessary.
Check blower wiring and blower
operation.
Check blower wiring and blower
operation.

Excessive noise.

Check blowers for damage.

Clean, tight, and damage free

No Action necessary.

Loose without wear.

Retighten to 90 lbs. tension. when

cold. Minimum of 50 lbs. when hot.

Oil Slicked/glazed/ or
excessively worn or damaged.
No unusual noise. No clutch
slippage: sharp engagement and
release. No oily dirt
accumulation on fittings or seals.
Good cooling.
No unusual noise. No clutch
slippage: sharp engagement and
release. No oily dirt
accumulation on fittings or seals.
Poor cooling.
No engagement. AC Mode "On";
No or low voltage.
Clutch slips, Voltage across
clutch coil above 9 V. (22V)

TXCR325.doc

No Action necessary.

14

Replace with new. Tension 1/2" belt

to 121 lbs., 5/8" to 132 lbs.
Clutch and compressor functioning
properly. No action necessary.

Check heater lines at cab floor. If

hot, there is a problem with heater
valve, heater control, or electrical
circuitry.
Troubleshoot electrical circuit.
Check refrigerant pressure.
Check for clutch wear. Turn off
machine. Maximum air gap is:
.031". Have clutch or compressor
replaced.

1/31/2008

Clutch slips, Voltage across coil

above 9 V. (22V)
Clutch slips, Voltage across coil
below 9 V. (22V)
Clutch cycles On and Off rapidly,
Poor cooling,

Unusual noise-AC cooling.

Unusual noise-AC not cooling.

Oily dirt accumulating behind
pulley or around compressor
seals.

Check condition of
Condenser
Assembly.

Weekly

AC On, Fans operating, coil free

of dirt and debris. No physical
damage.
AC On. Fans not turning; clutch
cycles off repeatedly. Poor
cooling.
AC On one or both fans turning
slowly. Poor cooling
Condenser coil clogged with dirt
and debris.
Condenser coil physically
damaged.
Secure without damage or
visible oil/dirt contamination on
unions.

Check condition of
AC and Heater
Hoses

Weekly

Worn or abraded.
Loose
Oil/dirt accumulation.

Check Receiver
Drier Sight Glass
with machine
operating in max.
AC mode.

TXCR325.doc

Sight glass clear. AC Cooling

properly.
Monthly

Sight glass is milky. AC cooling

properly.
Sight glass has large bubbles or
is milky. AC not cooling properly.

15

Excessive discharge pressure.

Check condenser fans and coils.
Determine cause and correct.
Troubleshoot electrical circuit.
Check compressor ground.
Low temperature machine
operation-move machine to warm
shed and repeat. Defective pressure
switch or condenser/charge issues.
Check compressor mount
components for tightness/ check air
gap for minimum clearance of .016"
and uniformity.
Worn or damaged clutch or
compressor. Discontinue operation
until serviced.
Indicates refrigerant and oil leak.
Have system promptly serviced.

No Action necessary.
Troubleshoot electrical circuit.
Check condenser ground, Relay,
Fuse.
Fan/s worn out. Replace.
Clean with air, soap and water, or
coil comb. Do not use sharp tools or
bend the fins.
Have AC system repaired
immediately. Delays will result in
more costly repair later on.
No Action necessary.
If AC hose have serviced. If heater
hose determine cause, rectify
problem and replace hose.
Re-secure with hose clamps or
nylon ties.
Indicates refrigerant and oil leak.
Have system promptly serviced.
No action necessary.
If over 80F, no action necessary. If
not may indicate slightly low charge
or refrigerant contamination. Have
serviced soon.
Probable low refrigerant charge.
Service AC system immediately.

1/31/2008

Service Procedure: Belt Tensioning (Model 9057)

1.
2.
3.
4.
5.

Removing the cover is recommended.

Loosen the two nuts holding the motor to the bracket.
Loosen the backing nut on tensioner bolt.
Tighten the tensioner bolt until the belt only deflects with moderate pressure. Belts broken in
for 10 minutes will deflect slightly more.
Re-tighten the motor nuts and backing nut.

CASE
DRAIN

TXCR325.doc

INLET
PORT

16

TENSIONER
BOLT

1/31/2008

SERVICE PARTS

02-VW7-016 BLOWER UNIT

No.

Qty

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15

1
1
2
1
2
1
4
1
1
2
1
1
1
1
1

Part No.
400093-A
463710-A
461236
463509
461983
80-RCF009
463402
78B-12010
461904
404981
461232
81-XEO010
462305
463504
465465

TXCR325.doc

Description
Switch, Master/Fan w/ Off (w/ 300701 Jam nut)
Switch, Mode (w/ 300701 Jam nut)
Knob w/ Set Screw
Switch, Rocker Lighted
Thumb Screw
Filter, Recirculated Air
Louver
Blower & Motor Assy
Switch, A/C Thermostat
O-ring #8
Coil, Evaporator
Valve, Expansion
Drain Tube
Drain Tube Valve
Wire Harness (not shown)

17

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17-9057-031 HYDRAULIC DRIVE UNIT

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14

Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1

TXCR325.doc

Part #
171-1.59-1
165-00H010
463947
168-12-325
461146
174-PS-010
12-SD-407A
550867
101-HD8017
463734
101-HD6022
82-00-001
403081
465467

Description
Motor, Hydraulic
Pulley
Hub, Split Tapered
Belt
Relay, 12V
Switch, Swing Sense 625 psi NO
Compressor
Fan Group
Hose Assy, Refrig. #8 Discharge (w/ (2) #8 O-rings (404981))
Coil, Condenser
Hose Assy, Refrig. #6 CD to RD (w/ (2) #6 O-rings (405011)
Receiver-Drier
Binary Switch
Wire Harness (not shown)

18

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12-SD-407A AC COMPRESSOR
No. Qty Part No.

Description

1,2,3

Clutch Assy, 12V

Oil, Refrigerant Sanden SP-20 8.45 oz can

122-SD4004
461976

Note: Use high strength thread-locker when installing shaft extension and threaded dowels on to the compressor
clutch. Do not torque the dowels so they deform the clutch plate!

550867 CLUTCH FAN ASSEMBLY

No. Qty Part No.
1
2
3
4
5
6
7
8
9
10

1
3
1
1
3
1
4
1
4
4

462659
463435
462660
462721

TXCR325.doc

Description
Shaft Extension
Threaded Dowel
Fan Spacer Hub
Blade, 14
Washer, Flat
HHCS 1/2" NF x 1 1/4
HHCS 5/16 NC x 3/4"
Washer Lock
Washer 5/16 Lock
Washer 5/16 Flat

19

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10-TX-325/A/B HOSE REPLACEMENTS

Machine

Qty

RT/T500,600,700

1
1
1
1
1
1
1
1
1

RT1120

RT/T200,300

Part #

Description

101-TX6017
101-LR0004
101-HD6025
101-TX6017
101-LR0004
101-HD6028
101-TX6020
101-TX0020
101-HD6029

Hose Assy, Refrig #6 RD-TXV (w/ (2) #6 O-rings (405011)

Hose Assy, Refrig #10 TXV Comp (w/ (2) #10 O-rings (405012)
Hose Assy, Hyd. -6 Case Drain
Hose Assy, Refrig #6 RD-TXV (w/ (2) #6 O-rings (405011)
Hose Assy, Refrig #10 TXV Comp (w/ (2) #10 O-rings (405012)
Hose Assy, Hyd. -6 Case Drain
Hose Assy, Refrig #6 RD-TXV (w/ (2) #6 O-rings (405011)
Hose Assy, Refrig #10 TXV Comp (w/ (2) #10 O-rings (405012)
Hose Assy, Hyd. -6 Case Drain

22-01-003 OUTSIDE AIR FILTER

No.

Qty

1
2
3
4
5
6

1
2
1
2
2
1

TXCR325.doc

Part #

Description

221-001
463428
221-002
463713
461987
80-OSP010

Base Filter
Retainer Nut
Cover, Filter
Washer
Thumb screw
Filter, Paper 1 X 6 X 9 3/8

20

1/31/2008

Appendix:

Typical Charge Amounts for Kenway units on are as follows:

AC System:

(Note: AC compressors supplied with Kenway systems have sufficient oil in them for the entire AC
system)
TXCR325:

2.25 lbs of 134a refrigerant.

Note: When replacing AC compressor remove unnecessary refrigerant oil.

Where to Get More Information:

AC Training:
Kenway How AC Works
Kenway AC Service and Troubleshooting
AC Websites:

www.macsw.com
www.sae.org
www.aircondition.com
www.ashrae.org

AC Book:

Troubleshooting and Servicing Modern AC and Refrigeration Systems by John Tomczyk

Upgrade Note:
This AC Only System is Oil Heat Upgradable. Contact Kenway Engineering for additional
information.

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Notes:
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________

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TXCR325.doc

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Sales * Service * Parts * Design * Engineering

2555 Lake Ave, Fairmont, MN 56031
Phone: 507-238-9051
Fax:

507-238-9998

sales@kenwayengineering.com
* AIR CONDITIONERS * ENGINE MOUNT KIT

HYDRAULIC HEATERS * AIR CONDITIONERS * ENGINE MOUNT KITS

Manufacturer, sales, service, parts and design for agricultural and industrial equipment

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