TEREX CRANE

OWNER’S MANUAL
TXCR326/H/A
A/C & Oil Heat System

TXCR326.doc REV NR 1 4/16/2008

TXCR326.doc REV NR 2 4/16/2008
 Owner’s Manual
TXCR326
(Model VW7 and 17-9057)

MACHINE SERIAL #:________________________

INSTALL/INSERVICE DATE:_________________

SERIAL #:__________________________________

TXCR326.doc REV NR 3 4/16/2008

 PRODUCT COVERAGE AND USAGE
HYD. DRIVE
TEREX MODEL KENWAY SYSTEM TEREX AF KIT
UNIT (H.D.U)
RT200-1/RT230/RT230-1/ RT230-
TXCR326 NA TXCR326-1 17-9057-30
1XL

RT300/RT300-1/RT335-1 SN:
TXCR326H NA TXCR326-1H 17-9057-30H
<15298

RT300/RT300-1/RT335-1 SN:
TXCR326 NA TXCR326-2 17-9057-30
>15297 (12/07)

RT500/RT500-1/RT555/ RT555-1
TXCR326H NA TXCR326-2H 17-9057-30H
SN: <15261

RT500/RT500-1/RT555/ RT555-1
TXCR326 NA TXCR326-2 17-9057-30
SN: >15260 (12/07)

RT600/RT665/ RT665-1 TXCR326 NA TXCR326-2 17-9057-30

RT700/RT775/ RT780 TXCR326 NA TXCR326-3 17-9057-30

RT1120 TXCR326A NA 17-9057-30

T335-1/T340-1/ T340-1XL TXCR326 NA TXCR326-1 17-9057-30

T560/T560-1 TXCR326 NA TXCR326-2 17-9057-30

T775 TXCR326 NA TXCR326-3 17-9057-30

39-TXCR325 Oil Heat Upgrade Kit.

Updates factory systems (TXCR325) shipped after 12/30/07 with the Kenway AC only system and
Suburban Propane Heat unit. Removal of Suburban heater is not required.

TXCR326.doc REV NR 4 4/16/2008

 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.

KENWAY OIL HEAT SYSTEM

Overview:
The Kenway Oil Heat System generates heat in the machines own hydraulic oil to be
used for Cab Comfort Heating. Hydraulic oil is pumped through a relief valve. The
change in pressure across the relief valve causes the oil to heat up. The oil then passes
through a heat exchanger inside the cab. Air from the cab is drawn through the heat
exchanger and is heated by the oil. The oil continues back to the pump where a portion
of it is exchanged with case drain oil from the hydraulic motor that drives the pump.

Below left is a typical cab unit. It consists of two heat exchanges and a blower with
motor. The lower heat exchanger is the AC systems evaporator coil. The top exchanger is
the Oil Heat Coil.

On the right is the MD 9057 Hydraulic Drive Unit. Its main components are: Hydraulic
drive motor; AC compressor: and the Oil Heat Pump.

TXCR326.doc REV NR 5 4/16/2008

 Kenway Oil Heat Details [Model 17-9057]:

AC
Compressor

Hyd. Heat
Pump
Hydraulic
Motor

The Hydraulic Drive Unit has three 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 has
either a dedicated pump; is a parallel circuit usually with flow control; or is in series with
another motor on the machine. On cranes, it is usually in series with the swing motor.

Hydraulic Oil Heat Pump

The Heat pump has a pair of manifolds attached to it. The “Heat Developer Manifold”
and the “Return Manifold”. Attached between the manifolds is a small filter/tank. Oil is
pumped (Bypass Mode) through the tank unless “Heat” mode is engaged. When heat
mode is engaged oil is pumped through the heat exchanger inside the blower unit

The pump does have a fixed rotation and must operate counter-clockwise as viewed
from the back of the pump.

Note: the AC compressor and Oil Heat Pump do not run concurrently. Mode selection
is determined by the operator.

TXCR326.doc REV NR 6 4/16/2008

Heat Developer Manifold contains the relief valve, bypass valve, cold start check valve,
and two diagnostic ports.

In Heat mode, the Bypass Valve closes and re-directs the oil
through the Electrical Proportional Relief Valve to generate
pressure on the oil being pumped.
The Proportional relief valve is normally open and has a
cracking pressure around 175 psig. When current is supplied to
the field coil from the Proportional Valve Controller the
pressure drop across the oil flow will increase. Increasing the applied
current increases the pressure-drop and heat output. Typical pressures
are limited to 2600 psig.

The Cold Start Check Valve (CV1) protects the heat coil and heater lines from
excessively high pressure. It will allow oil to bypass through the tank. This normally
will only occur at startup when the oil is cool and thick but can also occur when the
pump is turning very fast.

The Diagnostic ports are for measuring the pressure before and after the Relief Valve.

The Return Manifold contains the hydraulic circuitry that allows the system to use the
machines’ hydraulic oil. It allows oil from the drive motors’ case drain
to trickle into the heat circuit. The circuit consists of a check valve and
an orifice which controls the amount of oil from the motor case drain
which is mixed with the oil in the heat circuit. The oil enters the
manifold block at the “MD” port through an inline check. The excess
case drain oil and old oil from heat circuit are drained from the top of
the tank. An oil schematic follows which shows these circuits. The
inline check valve prevents oil from draining out of the heater circuit.
This manifold also contains the high oil temperature cutout switch.

TXCR326.doc REV NR 7 4/16/2008

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).
• The heat range selector is continuously variable rotary switch. The lowest switch
position cuts power to the relief valve. Clockwise rotation increases the pressure
drop and associated heat output.
• The Swing Sense Selector Switch allows the operator to select or deselect “Swing
Sense Mode”. When Swing Sense mode is 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 (AC Mode) or reduce the power used by the heater (Heat
Mode).
Warning: Operating the crane with Swing Sense “Disabled” can result in
fluctuations of swing speed when the AC clutch or Heat is activated or
inactivated.

Automatic

• The Proportional Valve controller regulates the current to the

proportional relief valve based on operator input and input from various
switches. The controller ramps the current to the relief valve over a five
second period. It is mounted to the relief valve field coil outside on the
pump.
• A Swing Sense Pressure Switch 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 and it signals the Proportional Valve
Controller to reduce heat output thereby giving power back to the swing.
• To protect the pump and oil from overheating, Kenway uses an Oil Temperature
Switch to limit the temperature of the oil returned to the pump. It is a normally
closed switch which opens at 205°F. When it opens it signals, the proportional
valve controller, which then cuts the current to the relief valve field coil. The oil
pressure slowly drops and heat generation quits. Since the pump is still turning,
oil circulates through the heat exchanger, which continues to give up heat from
the oil. When the oil temperature cools to about 175°F, the oil temperature switch
will close and the heating process will resume.
• On the AC side, a Thermostat switch prevents evaporator coil freeze-up and a
Binary pressure switch protects the AC systems from excessively high or low
system pressures.

TXCR326.doc REV NR 8 4/16/2008

 Maintenance:
A H
Check/
I e
Check Inspection Observation Action/Remedy
r a
point
t
X X Clean and damage free Re-install.
Remove Blow clean with low pressure air
Recirculation X X Impregnated with dust and dirt
gun or wash with soap and water.
Air filter. X X
Worn out or torn. Replace with new.

D Remove and
inspect Fresh X
X
X
Clean and damage free.

Impregnated with dust and dirt

Re-install
Blow clean with low pressure air

a Air filter. gun.

X X
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

i coil for dirt contamination and clean with warm water and soap to get optimum AC and heat
performance.
Distinctive airflow change for each

l X X speed. No unusual noises from

blowers.
No Action necessary.

y Check Cab
Blower Motor
X X Systems doesn't power up. Check fuses.

X X No fan speeds. Check fan resistor.

X X Excessive noise. Check blowers for damage.

TXCR326.doc REV NR 9 4/16/2008

 Maintenance:
H
Check/ A
e
Check Inspection I Observation Action/Remedy
a
point r
t

X X Clean, tight, and damage free No Action necessary.

Check
Compressor Retighten to 90 lbs. tension. when cold.
X X Loose without wear.
W Or
Heat Pump
Drive Belt
Oil Slicked/glazed/ or excessively
Minimum of 50 lbs. when hot.

Replace with new. Tension 1/2" belt to

X X

e worn or damaged.

AC On, Fan operating, coil free of

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

X dirt and debris. No physical No Action necessary.

e X
damage. Good Cooling
AC On. Fan not turning, clutch
cycles off repeatedly. Poor
Troubleshoot electrical circuit. Check
condenser ground, Relay, Fuse.

k Check
condition of
Condenser
X
cooling.
AC On and fan turning slowly.
Poor cooling
Fan worn out. Replace.
Assembly.
l X
Condenser coil clogged with dirt
and debris.
Clean with air, soap and water, or coil
comb. Do not use sharp tools or bend the
fins.
Have AC system repaired immediately.

y X
Condenser coil physically
damaged.
Delays will result in more costly repair
later on.
Secure without damage or visible
X X No Action necessary.
oil/dirt contamination on unions.
If AC hose have serviced. If heater hose
X X Worn or abraded. determine cause, rectify problem and
replace hose.
Check
condition of AC
X X Loose Re-secure with hose clamps or nylon ties.
and Heater
Hoses

Indicates refrigerant and or oil leak. Have

X X Oil/dirt accumulation.
system promptly serviced.

TXCR326.doc REV NR 10 4/16/2008

 Maintenance:
H
Check/ A
e
Check Inspection I Observation Action/Remedy
a
point r
t
No unusual noise. No clutch
slippage: sharp engagement and
X X No Action necessary.
release. No oily dirt accumulation
on fittings or seals.
No engagement. AC Mode "On"; Troubleshoot electrical circuit. Check
X X
No or low voltage. refrigerant pressure.
Air Conditioner Check for clutch wear. Turn off machine.
Clutch slips, Voltage across
Clutch X X Maximum air gap is: .031". Have clutch or
clutch coil above 9 V. (22V)

M X
Clutch slips, Voltage across coil
above 9 V. (22V)
compressor replaced.
Excessive discharge pressure. Check
condenser fans and coils. Determine

o
cause and correct.
Clutch slips, Voltage across coil Troubleshoot electrical circuit. Check
X X
below 9 V. (22V) compressor ground.

n
Remove Pressure or temperature
Replace oil and Troubleshoot oil
Oil heat X switch and check for poor quality
exchange circuit.
of oil in heat circuit.
Low ambient temperature move machine

t X
Clutch cycles On and Off rapidly,
Poor cooling,
to warm shed and repeat. Low refrigerant
charge-discontinue AC operation until
serviced.

h Air Conditioner
Compressor
X Unusual noise-AC cooling.
l X
Check compressor mount components for
tightness/ check clutch air gap for
minimum clearance of .016" and
uniformity.
Unusual noise-AC not cooling.
Worn or damaged clutch or compressor.
Discontinue operation until serviced.
Oily dirt accumulating behind

y X pulley or around compressor

seals.
Sight glass clear. AC Cooling
Indicates refrigerant and oil leak. Have
system promptly serviced.

X No action necessary.
Check properly.
Receiver Drier If over 80°F, no action necessary. If not
Sight Glass Sight glass is milky. AC cooling may indicate slightly low charge or
X
with machine properly. refrigerant contamination. Have serviced
operating in soon.
max. AC mode. Sight glass has large bubbles or Probable low refrigerant charge. Service
X
is milky. AC not cooling properly. AC system immediately.

TXCR326.doc REV NR 11 4/16/2008

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.
Precaution:
• 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.

TXCR326.doc REV NR 12 4/16/2008

Electrical Service Tools:
List:
• Digital Multimeter
• 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.

TXCR326.doc REV NR 13 4/16/2008

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!

The Electrical Schematic follows.

TXCR326.doc REV NR 14 4/16/2008

SCHEMATIC, ELECTRICAL AIR AND OIL HEAT SYSTEM W/
MODEL VW7 BLOWER AND MODEL 9057 HYDRAULIC DRIVE
UNIT. (29-HYD-025)

ITEM PART # DESCRIPTION

1 400093-A SWITCH, MASTER PWR & FAN SPEED
2 78B-12010 BLOWER, W/ 3-SPD RES.
3 463710 SWITCH, MODE-ROTARY
4 461904 SWITCH, AC THERMOSTAT-FIXED
5 403081 SWITCH, AC BINARY PRESSURE
6 122-SD4004 CLUTCH, AC COMPRESSOR
9 179-013 VALVE FIELD COIL
10 463612 POTENIOMETER ASSY
SWITCH, SWING SENSE PRESSURE
11 174-PS-010 (NO)
RESISTOR, HT PWR UNLOADING (7.5
12 465311 (2x) KOHM)
13 174-SR-004 SWITCH, OIL TEMPERATURE (NC)
PROPORTIONAL VALVE
14 173-VC-003 CONTROLLER
15 179-12-01 VALVE FIELD COIL (DIN)
16 461146 RELAY
17 463509 SWITCH, LIGHTED ROCKER

Connector “D”

PINOUT WIRE LABEL

D-1 C AC

D-2 P SS

D-3 PH

D-4 CTR O

D-5 CTR I

D-6 CTR G

TXCR326.doc REV NR 15 4/16/2008

 Maintenance & Basic Troubleshooting:
Check/ Inspection Inspection
Observation Action/Remedy
point Interval
Clean and damage free Re-install.
Remove Daily/
Blow clean with low pressure air gun
A Recirculating Air Application Impregnated with dust and dirt
or wash with soap and water.
filter. Dependent
Worn out or torn. Replace with new.
Clean and damage free. Re-install
Blow clean with low pressure air
Impregnated with dust and dirt
gun.
Remove and Daily/
B inspect Fresh Air Application Worn out, un-cleanable or torn. Replace with new.
filter. Dependent 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.

Check Cab Follow operation instructions at the

C Monthly
Controls. beginning of this manual.
System powers down and up. No Action necessary.
Power Off/ Power
1 Systems doesn't power up or
On Check fuses.
down.
Distinctive air flow change for
each speed. No unusual noises No Action necessary.
from blowers.
Check blower Check blower wiring and blower
2 No blower operation
speeds operation.
Check blower wiring and blower
No fan speeds.
operation.
Excessive noise. Check blowers for damage.
Clean, tight, and damage free No Action necessary.

Check Compressor Retighten to 90 lbs. tension. when

D Weekly Loose without wear.
Drive Belt cold. Minimum of 50 lbs. when hot.
Oil Slicked/glazed/ or Replace with new. Tension 1/2" belt
excessively worn or damaged. to 121 lbs., 5/8" to 132 lbs.
No unusual noise. No clutch
slippage: sharp engagement and
Clutch and compressor functioning
release. No oilly dirt
properly. No action necessary.
accumulation on fittings or seals.
Good cooling.
No unusual noise. No clutch
Turn on AC and Check heater lines at cab floor. If
slippage: sharp engagement and
check compressor hot, there is a problem with heater
release. No oilly dirt
E clutch and Monthly valve, heater control, or electrical
accumulation on fittings or seals.
compressor circuitry.
Poor cooling.
operation.
No engagement. AC Mode "On"; Troubleshoot electrical circuit.
No or low voltage. Check refrigerant pressure.
Check for clutch wear. Turn off
Clutch slips, Voltage across machine. Maximum air gap is:
clutch coil above 9 V. (22V) .031". Have clutch or compressor
replaced.

TXCR326.doc REV NR 16 4/16/2008


Check condition of
F Condenser Weekly
Assembly.
Check condition of
G AC and Heater Weekly
Hoses
Check Receiver
Drier Sight Glass
H with machine Monthly
operating in max.
AC mode.
TXCR326.doc REV NR
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.
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.
Worn or abraded.
Loose
Oil/dirt accumulation.
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.
17
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 80°F, no action necessary. If
not may indicate slightly low charge
or refrigerant contamination. Have
serviced soon.
Probable low refrigerant charge.
Service AC system immediately.
4/16/2008
Service Procedure: General AC
z Take care to prevent entry of dirt in to the system components.
z Rotate compressor 2-3 times prior to charging to prevent liquid
compression.
z Remove caps and plugs just before connecting. (Caution:
Compressor is pressurized)
z Do not knock or drop components.
z Piping Precautions:
1. Position o-ring against pipe upset when connecting lines.
2. Coat o-ring and connection faces with refrigerant oil.
3. Fit male pipe into female before starting the threads.
4. Use back up wrench whenever possible.
z Fitting Torque Specifications (o-ring):
Fitting Size Thread Size Ft/lb
#6 5/8-16 11-13
#8 3/4-16 15-20
#10 7/8-14 21-27

Service Procedure: Flushing

Procedure to follow when flushing a system to remove debris and oil form an automotive
air-conditioning system.
• Each individual component needs to be flushed separately. Removal of hoses or
any other devices may be needed for proper flushing.
• Do not flush the receiver/drier, compressor, or expansion valve. These items need
to be replaced.
• Flush system with an approved A/C flushing agent (contact local auto parts store
or check out the internet).
• A flush gun helps to get the flushing agent through the components correctly.
Procedure:
1. Follow the instructions of the flushing kit.
2. After using the flushing agent use compressed air to blow any residue left
behind from the flushing process. It also helps to place your finger or a
shop rag on the opposite end to create some back pressure to dislodge any
debris. It's best to perform this procedure many times in both directions to
achieve the cleanest system possible.
3. Repeat: 1 &2. After you think it is clean, do it again you can never have a
clean enough system. Some condensers and evaporators are very difficult
to flush and may need to be replaced. It is cheaper to replace them than to
have debris left in the system which can damage new components.
4. A final flush with nitrogen after the flushing stage is recommended to
remove any moisture that maybe left behind by the shop air.
5. At this point, replace the damage components.
6. Add the correct type and amount of oil.
7. Evacuate and recharged. Evacuation should be done for a minimum of one
hour.

TXCR326.doc REV NR 18 4/16/2008

Service Procedure: Refrigerant Charging
Charging an Air Conditioning System (New or Completely
Empty)
Notes: 1) The ambient must be above 60 degrees Fahrenheit to evacuate and charge
an air conditioning system. The refrigerant tank may be placed in a pail of
warm water to raise the tank pressure to facilitate charging. Tank pressure
must be higher than system pressure to charge system. The typical tank
pressure for charging is 40-100 psi.

2) The refrigerant service hoses must have shutoff valves within 12” of the end
of the service hose to be attached to the A/C system to be serviced.

Caution: Refrigerant is under pressure. Use safety goggles to prevent eye injury and
gloves to prevent frostbite. Do not wear loose clothing that may get caught in
moving parts.

The following steps will describe how to charge an R-12 or R-134a air conditioning
system that uses a receiver drier with a sight glass using the vapor only charging method.

Step 1: Remove the protective caps from the charging ports on the A/C system to be
charged.
Step 2: Connect the blue low side service hose to the blue compound suction gauge on
the manifold gauge set and to the suction service port on the largest line at
or near the compressor on the A/C system.
Step 3: Connect the red high side service hose to the red discharge gauge on the
manifold gauge set and to the discharge service port at or near the
compressor on the high pressure line on the A/C system.
Step 4: Connect the yellow supply hose to the center connection on the manifold gauge
set and to the suction port on the vacuum pump. Evacuate for a minimum
of 45 minutes.
Step 5: Close the manifold gauge valves. Disconnect the yellow supply hose from the
vacuum pump and connect it to the refrigerant tank.
Step 6: Purge any non-condensable (air) out of the yellow supply hose (refrigerant tank
to manifold gauge set).
Step 7: Place the bulk refrigerant tank on a certified scale to either weigh in the
specified amount or refrigerant or to record the amount of refrigerant the
technician puts into the system for future reference.
Step 8: Open the blue low side valve a little at first to allow the refrigerant to enter the
system slowly, and then open the low side valve all the way. Do not open
the high side valve. If you were to open it and forget to close it when
the machine is started and the air conditioner is turned on, the high
side pressure could cause the refrigerant tank to explode! Observe the
gauges, the low side and the high side should equalize at the same pressure
as the refrigerant tank.

TXCR326.doc REV NR 19 4/16/2008

Step 9: Check for leaks with a leak detector. If leaks are found, correct the problem and
if necessary go back through the preceding steps before continuing on to
step #10.
Step 10: Start the machine and turn the air conditioning on to its maximum setting –
toggle switch set to air conditioning, fans on high, thermostat set to
maximum cool and the doors and windows open.
Step 11: Monitor the scale as to amount of refrigerant charge that has been pulled into the
system. When the specified amount for the system is reached, close the
valve on the refrigerant tank then the valve on the gauge set.
Step 11a: If the charge amount is unknown, see Method: Seat-of-Pants Vapor
Charging.
Step 12: Allow the system to run for three-five minutes. Place a thermometer in the
louver closest to the blower motor. Record louver temperature, ambient
temperature, and pressures for future reference. Check the refrigerant sight
glass on the receiver drier. The sight glass can be clear or milky but should
not have a steady stream of large bubbles circulating through it. Large
bubbles can indicate a contaminated refrigerant charge (air) or insufficient
charge. Follow method as describe in “Seat-of-Pants Vapor Charging “
section to determine whether the refrigerant charge is low.
Terex Crane: Typical Charge Amounts for Kenway units on are as follows:
(Note: compressors supplied with Kenway systems have sufficient oil in them for the
entire system)
RT and Upper systems: 2.0 lbs of 134a refrigerant.
CD 100 and 200 series: approx. 3.0 lbs of 134a refrigerant.
Trucks or lowers approx. 2.75 lbs of 134a refrigerant.

TXCR326.doc REV NR 20 4/16/2008

 Method: Seat of the Pants Vapor Charging
The theory for this method is, when a TXV/receiver-drier system goes into
overcharge, the RD is completely full of liquid refrigerant so any additional
refrigerant added to the system will liquefy and back up into the condenser coil.
This decreases the amount of condenser used for condensing. In order to remove
the heat generated from the evaporator, the discharge pressure must increase and
since the liquid refrigerant is in the condenser longer it is subcooled more. Under
laboratory type conditions, factory charges are determined by measuring
subcooling and other system parameters,

Many AC technicians have very good luck charging R-134a systems without
measuring subcooling. They basically charge a system like an R-12 system but
carefully monitor the discharge pressure.

Since in ambient temperatures higher then 80° F, the sight glass of the receiver
drier may not become clear, the technician watches for the bubble size reduction.

If the sight glass clears, he will add an additional .5 to 1.0 lbs depending on size
of the receiver drier. If the discharge gauge reading should jump and remains
elevated, he will need to remove some refrigerant to restore the discharge
pressure reading.

If the sight glass doesn’t clear, he will gradually add refrigerant and monitor the
discharge pressures. When the pressure creeps up 5-10 psi he will stop and
sometimes recover some of the refrigerant.

Care must be taken that no other factors are affecting the discharge pressure. An
example is the technician is charging in a garage which continuously warms up
during the charging process. The discharge reading gauge reading will climb as a
result of the ambient temperature change.

Conclusion:
This method relies on monitoring charges in a measurable AC system parameter.
The technician must use his knowledge and experience to make a judgment,
which takes in the affects of environmental changes during the charging process
to determine whether the system is properly charged.

Another resource for technicians to obtain information is the Mobile Air

Conditioning Society. They can be reached using the Internet at
http://www.macsw.org/

TXCR326.doc REV NR 21 4/16/2008

Service Procedure: Refrigerant Recovery
• Refrigerant should never be vented to the atmosphere.

• R-12 destroys our Ozone layer.

• R-134a has a Global Warming Potential.

• Today’s refrigerant recovery equipment is very easy to use.

• For more information go to: www.macsw.com and www.epa.com

• Prior to recovery, run AC system at the lowest speed possible for 5

minutes.

• This will return most of the refrigerant oil back to the compressor.

• Follow the Recovery equipment manufacturer’s instructions.

The Federal government requires certification for R-12 serving.

Also, many states require Refrigerant recovery certification for any AC work.
Go to www.macsw.com for automotive certification. (It’s Cheap, Simple, and Online)

Service Procedure: Leak Detection

There are two generally used methods of refrigerant leak detection.
They are Electronic Sensing method and an UV Light/Dye method.

Tips for Electronic Sensing Method:

• Cannot check if air is moving.
• Refrigerant is heavier then air.
• Check high side immediately after turning off machine.
• Check low side after pressures equalize.
• Check for evaporator leaks at condensate drain.
• Check Compressor front seal and rear gasket.
Tips for UV/Dye Method:
• Be extremely careful that dye is compatible with the compressor oil as well as the refrigerant.
Catastrophic system failure can occur.
• Follow manufacturer instruction carefully. Too much dye can harm a system.

TXCR326.doc REV NR 22 4/16/2008

OIL HEAT SERVICING AND TROUBLESHOOTING

Service Tools:
• Digital Multimeter.
• Photo-tachometer.
• Hydraulic Test Gage with diagnostic port adapter: 3000 psi (Kenway #: 178-GG-
3000) Or/ Kenway#: 179-TEST KIT (includes both gages.)
• Hydraulic Test Gage with diagnostic port adapter: 160 psi (Kenway #: 178-GG-
160)

Service Warnings and Precautions:

Service Warnings:
• Surfaces can be Hot!
• Be aware of high-pressure discharges.
• Always wear safety glasses and protective gloves.
• Do not wear loose clothing that may get caught in moving parts.
• The hydraulic drive unit may also have Air Conditioning components. They
should only be disturbed by a qualified technician.
• Surfaces maybe slippery! Take care while moving about the machine.

Service 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 in appendix for
additional information.

Service Procedure: General

Prior to any Service work the following should be checked.
• Prior to engaging the heat pump, insure that the motor is turning the proper way.
All models to date turn the motor Clockwise when viewed from the shaft end.
• Check all electrical connections.
• Check hoses for routing problems like kinks or possible abrasion or slicing.
• Check for oil leaks.
• Check Belt tension.
• With the machine engine “Off”, check electrical operation of the blower, clutches,
etc.
• Check oil level in heat circuit.

TXCR326.doc REV NR 23 4/16/2008

 Service Procedure: Oil Charging (TXCR326)
CASE
DRAIN
FITTING

OPTIONAL-FILL
THIS LINE FIRST
TO FILL HEAT
COIL FROM
BOTTOM UP.

CASE DRAIN HOSE

WARNING:
Failure to pre-charge the heat circuit will result in pump failure.

Oil charging the oil heat circuit is critical for proper operation. It is necessary to
completely remove all air from the circuit prior to operating the machine.

The procedure is to pre-fill the oil heat system from its highest point then to allow the
motor case drain to force out any air still in the circuit prior to operating the pump in heat
mode.
1. Remove the case drain hose and 90 degree fitting from the top of the tank.
2. Pour hydraulic fluid into the tank, occasionally rotating the pump shaft by hand. A
typical system holds about 1.5 quarts of oil.
3. Re-install the adapter fitting and case drain hose.
4. Connect a low pressure gauge (0-300 psig) to the ‘DH’ port.
5. Turn “OFF” all heat and ac controls including the heat level selector and start engine.
6. Turn Mode Selector to AC mode and fan speed to “high”. Allow engine to run at
1400 rpm for 10 minutes. If there is no pressure at DH shut down machine
immediately because there is no oil in the pump. Go back to step 1.
7. With the machine idling and pressure at DH, move the low pressure gage to DL and
install a high pressure gage ( minimum 3000 psi) to DH.
8. Turn master control to Heat mode. Watch the high pressure gauge, if it spikes over
500-psi turn “OFF” heat clutch switch immediately. There is too much air in the
system.

TXCR326.doc REV NR 24 4/16/2008

9. If there is too much air in the system, turn off machine and top off oil charge in lines.
10. Repeat steps 1 thru 8 until high pressure gauge reads fairly steady.
Tip: When all air is purged from the system, turn up heat level switch inside the cab.
11. Check pressures. High pressure should not excess 2600 psig. As the oil warms, the
pressure may drop slightly. The temperature of the air at the louver inside the cab
should increase dramatically. At low pump speeds, the low pressure gauge should
read very low 10-20 psig and at high speeds pressure can approach 100 psig.

Note: If the DH gage pressure is erratic or low, cycle to the mode switch from heat to ac
mode and back every 10 seconds. The DH gage pressure should level off at the
appropriate pressure.

Warning:
Operating the heat pump with air in the system can cause the relief-valve to stick
completely closed (3000+ psig @ DH). Prior to sticking, the gauge readings will
fluctuate dramatically.

Caution:
Only qualified hydraulic repair technicians, fully aware of the hazards should perform the
above procedure. Take all necessary precautions when working with hydraulic
components. Beware of hot surfaces and high-pressure oil discharges.

Alternate Method:

Typical factory charging method is to install a bleed line at the “DL” port and run it into a
pail. AN air pressure regulator is then attached to the machine hydraulic reservoir tank
which is then pressurized with air pressure. Oil is then forced up the case drain line into
the top of the Kenway filter/tank. To ensure complete oil charging, turn the ignition key
to accessory and turn on the Kenway unit to Low Fan and Heat Mode. This will close the
bypass valve and force the oil to go through the heat exchanger. Continue this operation
until the oil runs clear (approximately 15 minutes).

Remove bleed line and complete steps 4 thru 11 abov

HIGH PRESSURE
PORT (DH)
Note: Port maybe found
on back of pump.

LOW
PRESSURE
PORT (DL)

TXCR326.doc REV NR 25 4/16/2008

Service Procedure: Belt Tensioning (Model 9057-30H)
Note: The Air and Oil Heat Model 9057 must have “matched” belts so always replace both belts.
1. Remove cover is recommended.
2. Loosen the four bolts to the motor bracket.
3. Tighten the tensioner bolt on the side of the unit until the belts only deflects ¼” with moderate
pressure. Hot belts will deflect more.
4. Re-tighten the motor bracket bolts.

TENSIONER
BOLT

TXCR326.doc REV NR 26 4/16/2008

Service Procedure: Belt Tensioning (Model 9057-30)
Note: The Air and Oil Heat Model 9057 must have “matched” belts so always replace both belts.
5. Remove cover is recommended.
6. Loosen the two nuts holding the motor to the bracket.
7. Loosen the backing nut on tensioner bolt.
8. Tighten the tensioner bolt until the belts only deflects ¼” with moderate pressure. Hot belts will
deflect more.
9. Re-tighten the motor nuts and backing nut.

TENSIONER
BOLT
INLET
PORT

TXCR326.doc REV NR 27 4/16/2008

Service Procedure: Proportional Valve Controller Adjustment

The settings on the Proportional Valve Control are factory set and should not need adjustment.
Should adjustments be necessary, remove the mounting screw and the transparent lid. The trim pots are
adjusted with a jeweler’s size screwdriver (slotted 1.5).

The Ramping potentiometers are ¾ turn and should be set in the full clockwise position.

The Dither potentiometers are ¾ turn and should be set half way.

The Minimum and Maximum Current pots are 10 turn trim pots. There are no stops on these pots and can
only be adjusted with feedback from a multi-meter and a special electrical adapter or with feedback from a
pressure gauge on the DH port.

With the cab control set to minimum heat, the minimum current pot should be turned clockwise until the
output current increases/ pressure increases and then backed down to the minimum.

With the cab control set to maximum heat, the maximum current pot should be turned clockwise until the
output current reached 93 mA or DH pressure reaches 2300 psig.

Troubleshooting:
z Low fixed DH pressure: Open circuit of potentiometer “leads” results in fixed output of 700 to
1000 psig. Repair wiring/ termination.
z High fixed DH pressure: If potentiometer “leads” get shorted output may go to 3000+ psig.
Replace controller.
z Note: Resistance for both valve field coils is 7.2 Ohms.

Connector Pinout:
Pin Controller Wire Color Wire Harness Designation Description
1 RED PG Power (+)
2 BLACK G Power (-) -Ground
3 BLUE N/A Not Used
4 WHITE CTR O Pot (+) 5V output
5 GREEN CTR I 10 K pot- wiper/ signal
6 BROWN CTR G Pot (-) (ref. Ground)

TXCR326.doc REV NR 28 4/16/2008

Basic Troubleshooting of the Oil Heat System
Procedure:

Visual Check:
• Check for hydraulic oil leaks.
• Broken, discolored or disconnected wiring.
• Pinched hydraulic lines.
• Check tension on drive belts.

Check the Controls:

• Does the cab unit blow air? Check fuse and electrical connections to the controls
and blower system. See electrical trouble shooting.
• Does the sound of the pump change when the mode switch is changed to heat
mode and when the heat switch is turned from the full counter-clockwise
position?

Electrical Check
• Electrical Service and Troubleshooting should occur before mechanical.
• Check for proper operation of electrical devices prior to starting the engine.
• 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 electronic control
circuits as found on the Kenway Proportional Valve controller. Never use a test
lamp!
• The electrical schematic appears on page 13.

Check the Mechanics

• Is the drive motor turning?
• Is it turning slowly?
• Is it turning in the proper direction? CCW as viewed from back.
• Do the heat lines/ pump or manifold block heat up?
• Is there an unusual noise coming from the motor or pump?
• Is the belt slipping?

On the following pages are a number of troubleshooting guidelines and diagnostic

problems. If a problem cannot be solved with them feel free to contact: Kenway
Engineering, Inc at 507-238-9051 between the hours of 8:00am to 4:30 pm CST

TXCR326.doc REV NR 29 4/16/2008

 Advanced Troubleshooting the Oil Heat System
Troubleshooting the Oil heat circuit requires measuring pressures, temperatures and rotational speeds. The following tools are
required.

• Digital Multi-meter.
• Photo-tachometer.
• Hydraulic Test Gage with diagnostic port adapter: 3000 psi (Kenway #: 178-GG-
3000) Or/ Kenway#: 179-TEST KIT (includes both gages.)
• Hydraulic Test Gage with diagnostic port adapter: 160 psi (Kenway #: 178-GG-
160)

Always perform a visual, electrical, and basic hydraulic inspection and repair before
proceeding with advanced hydraulic troubleshooting.

Troubleshooting diagnostics follows with a hydraulic schematic with circuitry and

operational data.

HIGH
PRESSURE
PORT (DH)

Alt. location on
back of pump

LOW
Manual Adjust Screw PRESSURE
(3/16” Allen Head) PORT (DL)
Normally turned fully
CCW for electronic
operation.

(Note: Phillips screw in

middle is an air bleed.)

TXCR326.doc REV NR 30 4/16/2008

 SCHEMATIC, OIL HEAT - MODEL 9057 EFFECTIVE 1/08)
(Selectable Swing Sense)

Normally Open: 625

PSIG-Close

TXCR326.doc REV NR 31 4/16/2008

 Model 9057 Hydraulic Heat Control w/ Swing Sense
Start

Set Master
Power & Fan
Speed "On"

Set to "Heat
Mode"

Poppet Valve Closes-

Forcing Pump flow
through Proportional
Relief Valve.

Set Points on Electronic

Vctrl is reduced when
Valve Control:
open switch adds
Max. Press. (2300 psi)
resistor to voltage
Min. Press (0 psi)
divider reducing Vctrl
Ramp Time (5 sec)
Dither (210 Hz) Hydraulic Power tranfer to NO
Swing Motor

Oil Temperature Limit

Heat Level Setting
Is Oil Temperature
switch "closed" and oil
Toil<205 F?
Protection
Valve control reads Vctrl and
Is Pressure Switch on Motor ramps pressure at relief valve up
Outlet "Open" and Swing not and down accordingly.
commanded?
(Vctrl=0V)= Min.Press.@ DH= 150
psi (Valvecracking pressure/ No
YES heat generation)
(Vctrl=5V) = Max. Press.@DH =
2300 psi (Maximum heat
YES generation at pump flow rate)

NO

Vctrl = 0V 0V<Vctrl <5V Set

because of open by Manual Heat
circuit. Level Setting

End

TXCR326.doc REV NR 32 4/16/2008

 OIL HEAT TROUBLESHOOTING

DL PORT DH PORT

Air in Hydraulic Circuit

Indication:
• There is little or no heat in cab.
• Manifold block on hydraulic pump is hot.
• The pressure at DH port is very high or fluctuating very erratically. DL is normal.

Diagnosis:
• Air in the hydraulic circuit is causing the proportional relief valve to close and block off flow to
heat coil. This typically only occurs at initial pump startup during the oil charging procedure.

Remedy:
• If DH pressure is very high and steady, the relief valve is stuck and must be replaced. If condition
has lasted for any period time, the pump may have been damaged and may need to be replaced.
• If valve is fluctuating, immediately turn off heat mode. See Oil Charging Procedure to purge air
from circuit.
• In previously operating and functioning units, air may have been pulled into the circuit by the
contraction of the machines cooling hydraulic oil, check all fittings for proper torque and inspect
o-ring seals at motor case drain and all fittings on the pump’s manifold block.

TXCR326.doc REV NR 33 4/16/2008

 OIL HEAT TROUBLESHOOTING

DL PORT DH PORT

Swing Sense Control Failure

Indication:
• There is little or no heat in cab.
• AC clutch will not engage. No cooling.
• In heat mode, the pressure at DH port is low. DL is normal.

Diagnosis:
• The Swing Sense Switch is open. This cuts power to the AC clutch and reduces the maximum heat
output.

Remedy:
• Check the Swing Sense Switch continuity with the engine off. If switch is closed, replace switch.
• If switch is open, attach a pressure gauge between the motor outlet and the next hydraulic device
(typically: swing valve assembly). The pressure is typically below 300 psig. If the pressure
exceeds the Swing Sense Switch setting a down stream hydraulic device has a problem. See the
equipment manufacturer to diagnose and repair.

TXCR326.doc REV NR 34 4/16/2008

 OIL HEAT TROUBLESHOOTING

DL PORT DH PORT

Proportional Relief Valve Failure

Valve Stuck Open Indication:
• There is little or no heat in cab.
• Manifold block on hydraulic pump is cold or just warm.
• The pressure at DH port is low.
• Pressure at DL is normal.

Valve Stuck Closed Indication:

• Uncontrolled heat in the cab.
• Manifold block is very hot.
• The pressure at DH port is very high
• Pressure at DL is low.

Diagnosis:
• Contamination has caused the relief valve to stick either open or closed.
• The heat valve control has been shorted out at the potentiometer leads.

Remedy:
• Remove the relief valve and inspect and replace as necessary.
• Replace the heat valve controller.

TXCR326.doc REV NR 35 4/16/2008

 OIL HEAT TROUBLESHOOTING

DL PORT DH PORT

Bypass Valve Failure

Indication:
• Heat On, DL is low.
• DH is very low.
• Pump and block maybe warm but heater lines are cold.

Diagnosis:
• Zero DL pressure indicates no oil flow through relief valve or heat exchanger.

Remedy:
• Remove check valve at CV1. Inspect and replace as necessary.

TXCR326.doc REV NR 36 4/16/2008

 OIL HEAT TROUBLESHOOTING

DL PORT DH PORT

Cold Start Check Valve Failure

Indication:
• No heat
• Heat On, DL is low.
• DH is normal.
• Tank/Filter is very hot.
• Pump and block hot but heater lines are cold.

Diagnosis:
• Low DL pressure indicates no oil flow through heat exchanger. DH pressure cycling is caused by
the oil high temperature limit switch cutting off power to the proportional pressure relief valve.

Remedy:
• Remove the valve, inspect and replace as necessary.

TXCR326.doc REV NR 37 4/16/2008

 OIL HEAT TROUBLESHOOTING

DL PORT DH PORT

Pump Failure
Indication:
• Heat On, DL is zero or very low.
• DH is very low.
• Pump and block maybe warm but heater lines are cold.

Diagnosis:
• Zero DL pressure indicates no oil flow.
• Pump is unable to develop enough pressure to overcome relief pressure.

Remedy:
• Replace pump assembly.

TXCR326.doc REV NR 38 4/16/2008

 OIL HEAT TROUBLESHOOTING

DL PORT DH PORT

Pump Over-Speeding
Indication:
• Loud high pitched noise coming from heat pump. On machines with varying flow to hydraulic
motor, the unit may run quieter at engine idle.
• There is lots of heat in the cab.
• Manifold block on hydraulic pump is hot.
• The pressure at the DH port cycle from one or two hundred psig to normal.
• Pressure at DL is normal.
• The speed of the pump is in excess of 3600 rpm.

Diagnosis:
• The high pressure bypass valve at CV1 is forced open because there is too much hydraulic oil flow
to the heat coil causing a back pressure of over 100 psig (See also Bypass Valve Failure). DH
pressure cycling is caused by the oil high temperature limit switch cutting off power to the
proportional pressure relief valve.

Remedy:
• Reduce speed of the pump by replacing the hydraulic drive motor with a larger displacement
motor.
• OR/ If the motor is being operating within its speed range, the motor drive pulley can be replaced
with smaller diameter pulley.
• Contact Kenway for help in resizing the motor or pulley.

TXCR326.doc REV NR 39 4/16/2008

 OIL HEAT TROUBLESHOOTING

DL PORT DH PORT

Line or Coil Blockage

Indication:
• There is little or no heat in cab.
• Manifold block on hydraulic pump is hot.
• The pressure at DH port is normal or more likely cycling from one or two hundred psig to normal.
• DL pressure is above normal pressure (100 psig or higher).
Diagnosis:
• A heater line or the heat coil has become blocked and the heated oil is bypassed internally in the
manifold block by way of CV1 (100 psi) check valve. DH pressure cycling is caused by the oil
high temperature limit switch cutting off power to the proportional pressure relief valve.

Remedy:
• Check heater line installation for kinks, pinches, or collapses.
• Check heat coil for contamination. It has been reported that the heat coil can be become clogged
with a thick slime (varnish) after years of use. Kenway recommends that the coil be replaced.

TXCR326.doc REV NR 40 4/16/2008

 OIL HEAT TROUBLESHOOTING

DL PORT DH PORT

Hydraulic Motor Turning Slow

Indication:
• Hydraulic Motor may stall out or turn very slow.
• There is little or no heat in cab.
• Manifold block on hydraulic pump is cold or just warm.
• The pressure at DH port is normal to low.
• Pressure at DL is low to none.

Diagnosis:
• Main relief valve in motor circuit may be set to low.
• Swing Valve maybe stuck or other device in circuit has a problem.
• Hydraulic motor may be too large for the machine oil flow.
• If the other machine function are operating properly, the hydraulic motor may have excessive oil
slippage.

Remedy:
• Consult machine manufacture for relief valve setting and adjustment procedure.
• Verify with Kenway on motor size (Replace if wrong motor).
• Replace motor if defective.

TXCR326.doc REV NR 41 4/16/2008

 5

02-VW7 (’08) SERVICE PARTS

*Oil Heat Upgrade Components (additional panels shown above are also provided in the kit)
No. Qty 12V 24V Part No. Description
1 4 X X 463402 Louver
2 1 X X 400093 Switch, Master/Fan w/ Off
3 2 X X 300701 Nut, Jam
4 1 X X 463710 Switch, Mode
5 1 X X 463612 Potentiometer Assy*
6 1 X X 461904 Switch, A/C Thermostat
7 1 X 78B-24010 Blower & Motor Assy
7 1 X 78B-12010 Blower & Motor Assy
8 1 X X 461232 Coil, Evaporator
9 1 X X 81-XEO010 Valve, Expansion
10 2 X X 404981 O-ring #8
11 1 X X 463127 Coil, Heat*
12 2 X X 461983 Thumb Screw
13 1 X X 80-RCF009 Filter, Recirculated Air
14 1 X X 463767 Decal, Control
15 3 X X 461236 Knob w/ Set Screw
16 1 X 463509 Switch, Lighted Rocker 12V
16 1 X 463695 Switch, Lighted Rocker 24V
17 1 X X 465465 Wire Harness

TXCR326.doc REV NR 42 4/16/2008

 17-9057-30/-30H SERVICE PARTS
No. Qty Part # Description
1 1 12-SD-407A Compressor
2 1 101-HD8017 Hose Assy, Refrig. #8 Discharge
3 1 463734 Coil, Condenser
4 1 101-HD6022 Hose Assy, Refrig. #6 CD to RD
5 1 82-00-001 Receiver-Drier
6 1 403081 Binary Switch
2 405011 O-ring, Refrig. #6
2 404981 O-ring, Refrig. #8
7 1 See table Motor Assy (see pg 46 to identify)
8 1 174-PS-010 Switch, Swing Sense 625 psi NO
9 1 101-HD6018 Hose Assy, Hyd. -6 Motor Drain (17-9057-30H)
9 1 101-HD6039 Hose Assy, Hyd. -6 Motor Drain (17-9057-30)
10 1 178-PMP-020 Pump Assy
12 2 101-HD8030 Hose Assy, Hyd. -8 HBA-TNK
13 2 178-FLTR-02 Tank/Filter
14 3 173-013 Field Coil, Bypass Valve
15 1 173-12-01 Field Coil, Relief Valve
16 1 173-VC-003 Controller, Proportional Valve
17 2 461146 Relay, 12V
18 1 550867 Fan Group
19 1 465466 Wire Harness
Model Motor Assy Motor Pulley Pulley Part# Pump Pulley Pulley Part# Belt (2 per)*
17-9057-30 178-1.59-01 6.75 165-HYD005 5.20 165-HYD006 168-12-425
17-9057-30H 178-2125-03 6.75 165-HYD005 5.20 165-HYD006 168-12-440
*Belts must be matched sets.

TXCR326.doc REV NR 43 4/16/2008

12-SD-407A
SERVICE
PARTS

No. Qty Part No. Description

1,2,3 1 122-SD4004 Clutch Assy, 12V
4 1 127-SD4001 Front Seal
5 1 121-SD8002 Rear Gasket
6 1 126-SD8002 Rear Plate
461976 Oil, Refrigerant Sanden SP-20 8.45 oz can

Note: Use high strength thread-locker when

installing shaft extension and threaded dowels on
to the compressor clutch.

550867 SERVICE PARTS

No. Qty Part No. Description
1 1 462659 Shaft Extension
2 3 463435 Threaded Dowel
3 1 462660 Fan Spacer Hub
4 1 462721 Blade, 14”
5 3 Washer, ½” Flat
6 1 HHCS 1/2" NF x 1 1/4”
7 4 HHCS 5/16” NC x 3/4"
8 1 Washer ½” Lock
9 4 Washer 5/16” Lock
10 4 Washer 5/16” Flat

TXCR326.doc REV NR 44 4/16/2008

 178-2125-03
SERVICE
PARTS

No. Qty Part # Description

1 1 171-2125-2 Motor, Hyd 7/8” Keyed Shaft (1.90” Center Section)
179-ORB-06 Outrigger Bearing Assy (consists of all below w/ brkt & spindle)
1 172-002 Seal, Front Shaft
2 1 179-BRG-04 Bearing
3 1 463964 Snap Ring, Int.
4 1 463813 Snap Ring, Ext.

178-1.59-01 Motor Assembly Breakdown

No. Qty Part # Description
1 1 171-1.59-1 Motor, Hyd 7/8” Straight Shaft
2 1 179-HUB-01 Hub
3 1 463947 Bushing 7/8” ID split with ¼ keyway
4 1 463243 Adapter #6MB-#6MJ

TXCR326.doc REV NR 45 4/16/2008

 1
9

DH PORT

Manual Adjust Screw

(3/16” Allen Head)
Normally turned fully CCW for
electronic operation.

(Note: Phillips screw in middle is an

air bleed.)

178-PMP-020 SERVICE PARTS

No. Qty. Part # Description
1 1 172-.610-1 Pump, Hyd ¾” Shaft
2 1 176-001 O-ring, Hyd. -117
3 1 173-DR-004 Valve, Hyd. Bypass
4 2 461593 Diagnostic Nipple
5 2 461591 Cap, Diagnostic Nipple
6 1 173-OR-001 Orifice, .040”
7 1 173-CK-003 Valve, Hyd. Cold Start Check 100 PSI
8 1 173-RL-004 Valve, Hyd. Electrical Proportional
9 1 173-CK-007 Check Valve, Inline 5 PSI
10 1 174-SR-004 Switch, Hyd. Temp
11 1 173-CK-006 Valve, Hyd. Check 10 PSI
12 1 173-OR-001 Orifice, .040” (Formally: 173-OR-002 (.080”))
13 1 176-005 O-ring, Hyd. -119
14 1 463749 Hub, ¾” Shaft

TXCR326.doc REV NR 46 4/16/2008

 39-TXCR325 HYDRAULIC DRIVE OIL HEAT UPGRADE

NO. QTY PART # DESCRIPTION NO. QTY PART # DESCRIPTION

1 1 178-PMP-020 Pump/Block Assy 15 1 178-TNK-03 Tank Assy
2 4 300246 Nut, Hex M10-1.5 16 2 300086 HHCS1/4-20 X 1.0"
3 4 300454 Washer, Lock M10 17 4 300080 Washer Flat 1/4 Id,
4 2 300311 HHCS M10 X1.5 X 30mm 18 2 463985 Nut, Hex 1/4-20 Nylock
5 1 179-HUB-01 Hub, Pulley 19 2 461146 Relay, 12 Volt
6 1 165-HYD005 Pulley 6.75" 2-Ag 20 2 464642 Screw, Button Hd 10-24 X 3/8
7 1 165-HYD006 Pulley 5.20" 2-Ag 21 2 465384 Nut, #10-24 Nylock
8 8 465449 SHCS 1/4-20nc X 3/4" 22 1 101-HD6027 Hose Assy, -6 Mtr -Rba
9 8 300055 Washer, Lock 1/4 23 1 101-HD8030 Hose Assy, -8 Hba-Tnk
10 2 168-12-425 Belt, 1/2 X 42.5 24 1 173-VC-003 Valve Ctrl-Prop.(12v)
11 2 300245 HHCS M10-1.5 X 35mm 25 1 173-12-01 Field Coil, Hyd Din 12v
12 1 179-BKT003 Bracket 26 1 173-013 Coil, Field 12v
13 2 463986 Seal, Flaretite -08 27 4 300004 Tie, Plastic 7"
14 1 465379 Adapter, #8mj - #8fj90 28 1 465466 Wire, Harness
Note: See page 42 for Oil Heat component installation inside the cab.

TXCR326.doc REV NR 47 4/16/2008

 10-TX-325/A/B HOSE REPLACEMENTS

Machine Qty Part # Description

RT/T500,600,700 1 101-TX6017 Hose Assy, Refrig #6 RD-TXV (w/ (2) #6 O-rings (405011)
1 101-LR0004 Hose Assy, Refrig #10 TXV –Comp (w/ (2) #10 O-rings (405012)
1 101-HD6025 Hose Assy, Hyd. -6 Case Drain
RT1120 1 101-TX6017 Hose Assy, Refrig #6 RD-TXV (w/ (2) #6 O-rings (405011)
1 101-LR0004 Hose Assy, Refrig #10 TXV –Comp (w/ (2) #10 O-rings (405012)
1 101-HD6028 Hose Assy, Hyd. -6 Case Drain
RT/T200,300 1 101-TX6020 Hose Assy, Refrig #6 RD-TXV (w/ (2) #6 O-rings (405011)
1 101-TX0020 Hose Assy, Refrig #10 TXV –Comp (w/ (2) #10 O-rings (405012)
1 101-HD6029 Hose Assy, Hyd. -6 Case Drain

22-01-003 SERVICE PARTS

No. Qty Part # Description

1 1 221-001 Base Filter
2 2 463428 Retainer Nut
3 1 221-002 Cover, Filter
4 2 463713 Washer
5 2 461987 Thumb screw
6 1 80-OSP010 Filter, Paper 1 ¼” X 6 ¼” X 9 3/8”

TXCR326.doc REV NR 48 4/16/2008

 Appendix:

Typical Charge Amounts for Kenway units on are as follows:

Hydraulic Oil: approximately 1- 1.5 quarts:

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

TXCR326: 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

TXCR326.doc REV NR 49 4/16/2008

HYDRAULIC COMPONENT TORQUE RECOMMENDATIONS

Coupling & Adapter

JIC 37 FLARE-STEEL
SIZE FT-LBS

DASH THREAD MIN MAX

-4 7/16-20 10 11

-6 9/16-18 17 19

-8 3/4-16 34 38

-10 7/8-14 50 56

-12 1 1/16- 12 70 78

-16 1 5/16- 12 94 104

-20 1 5/8-12 124 138

SAE O-RING BOSS-STEEL

SIZE FT-LBS

DASH THREAD MIN MAX

-4 7/16-20 14 16

-6 9/16-18 24 26

-8 3/4-16 37 44

-10 7/8-14 50 60

-12 1 1/16- 12 75 83

-16 1 5/16- 12 111 125

-20 1 5/8-12 133 152

Valves & Other Components

KW# Description Port Torque

173-RL-004 PROPORTIONAL RELIEF VALVE (HYDRAFORCE) -10 ORB 25 FT-LBS MAX

173-RL-006 PROPORTIONAL RELIEF VALVE (PARKER-WATERMAN) -10 ORB 25 FT-LBS MAX

173-CK-001 CHECK VALVE, 4 PSI -8 ORB 20 FT-LBS MAX

173-CK-002 CHECK VALVE, 25 PSI -8 ORB 20 FT-LBS MAX

173-CK-003 CHECK VALVE, 100 PSI -8 ORB 20 FT-LBS MAX

173-CK-004 CHECK VALVE, 30 PSI -8 ORB 20 FT-LBS MAX

173-CK-005 CHECK VALVE, 5 PSI -8 ORB 20 FT-LBS MAX

173-CK-006 CHECK VALVE, 10 PSI -8 ORB 20 FT-LBS MAX

174-SR-004 OIL TEMPERATURE SWITCH -8 ORB-BRASS 20 FT-LBS MAX

174-PS-001 OIL PRESSURE SWITCH -4 ORB-BRASS 11 FT-LBS MAX

461593 DIAGNOSTIC PORT NIPPLE -6 ORB

TXCR326.doc REV NR 50 4/16/2008

Notes:

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TXCR326.doc REV NR 51 4/16/2008

 Sales * Service * Parts * Design * Engineering

2555 Lake Ave, Fairmont, MN 56031

Phone: 507-238-9051

Fax: 507-238-9998

sales@kenwayengineering.comHYDRAULIC HEATERS * AIR CONDITIONERS *

ENGINE MOUNT KIT
HYDRAULIC HEATERS * AIR CONDITIONERS * ENGINE MOUNT KITS
Manufacturer, sales, service, parts and design for agricultural and industrial equipment

TXCR326.doc REV NR 52 4/16/2008