Owner’s Manual

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

MACHINE MODEL:_____________________

MACHINE SERIAL #:___________________

BLOWER SERIAL #:____________________

HYDRAULIC DRIVE SERIAL #:__________

INSTALL/INSERVICE DATE:_____________

TXCR325.doc 1 1/31/2008
TXCR325.doc 2 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.

TXCR325.doc 3 1/31/2008
 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.

TXCR325.doc 4 1/31/2008
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 (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.

TXCR325.doc 5 1/31/2008
 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.

TXCR325.doc 6 1/31/2008
 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.

TXCR325.doc 7 1/31/2008
 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.

TXCR325.doc 8 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.
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.

Electrical Service Tools:

List:
• Digital Multimeter

TXCR325.doc 9 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.

TXCR325.doc 10 1/31/2008
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.

TXCR325.doc 11 1/31/2008
SCHEMATIC, ELECTRICAL AC ONLY SYSTEM W/ MODEL VW7
BLOWER AND MODEL 9057 HYDRAULIC DRIVE UNIT.
(29-HYD-033)

ITEM PART # DESCRIPTION

1 400093-A SWITCH, MASTER PWR & FAN SPEED
2 78B-12010 BLOWER, W/ 3-SPD RES.
3 463710-A SWITCH, MODE-ROTARY
4 461904 SWITCH, AC THERMOSTAT-FIXED
5 403081 SWITCH, AC BINARY PRESSURE
6 122-SD4004 CLUTCH, AC COMPRESSOR
11 174-PS-010 SWITCH, SWING SENSE PRESSURE (NO)
16 461146 RELAY
17 463509 SWITCH, LIGHTED ROCKER
END

TXCR325.doc 12 1/31/2008
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 507-238-
9051 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)

TXCR325.doc 13 1/31/2008
 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 oily 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 oily 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.

TXCR325.doc 14 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.
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.

AC On, Fans operating, coil free

of dirt and debris. No physical No Action necessary.
damage.
AC On. Fans not turning; clutch Troubleshoot electrical circuit.
cycles off repeatedly. Poor Check condenser ground, Relay,
cooling. Fuse.
Check condition of AC On one or both fans turning
F Condenser Weekly Fan/s worn out. Replace.
slowly. Poor cooling
Assembly.
Clean with air, soap and water, or
Condenser coil clogged with dirt
coil comb. Do not use sharp tools or
and debris.
bend the fins.
Have AC system repaired
Condenser coil physically
immediately. Delays will result in
damaged.
more costly repair later on.
Secure without damage or
visible oil/dirt contamination on No Action necessary.
unions.
If AC hose have serviced. If heater
Check condition of Worn or abraded. hose determine cause, rectify
G AC and Heater Weekly problem and replace hose.
Hoses
Re-secure with hose clamps or
Loose
nylon ties.
Indicates refrigerant and oil leak.
Oil/dirt accumulation.
Have system promptly serviced.
Sight glass clear. AC Cooling
No action necessary.
properly.
Check Receiver
If over 80°F, no action necessary. If
Drier Sight Glass
Sight glass is milky. AC cooling not may indicate slightly low charge
H with machine Monthly
properly. or refrigerant contamination. Have
operating in max.
serviced soon.
AC mode.
Sight glass has large bubbles or Probable low refrigerant charge.
is milky. AC not cooling properly. Service AC system immediately.

TXCR325.doc 15 1/31/2008
Service Procedure: Belt Tensioning (Model 9057)
1. Removing the cover is recommended.
2. Loosen the two nuts holding the motor to the bracket.
3. Loosen the backing nut on tensioner bolt.
4. Tighten the tensioner bolt until the belt only deflects ¼” with moderate pressure. Belts broken in
for 10 minutes will deflect slightly more.
5. Re-tighten the motor nuts and backing nut.

TENSIONER
CASE INLET BOLT
DRAIN PORT

TXCR325.doc 16 1/31/2008
 SERVICE PARTS

02-VW7-016 BLOWER UNIT

No. Qty Part No. Description

1 1 400093-A Switch, Master/Fan w/ Off (w/ 300701 Jam nut)
2 1 463710-A Switch, Mode (w/ 300701 Jam nut)
3 2 461236 Knob w/ Set Screw
4 1 463509 Switch, Rocker Lighted
5 2 461983 Thumb Screw
6 1 80-RCF009 Filter, Recirculated Air
7 4 463402 Louver
8 1 78B-12010 Blower & Motor Assy
9 1 461904 Switch, A/C Thermostat
10 2 404981 O-ring #8
11 1 461232 Coil, Evaporator
12 1 81-XEO010 Valve, Expansion
13 1 462305 Drain Tube
14 1 463504 Drain Tube Valve
15 1 465465 Wire Harness (not shown)

TXCR325.doc 17 1/31/2008
 17-9057-031 HYDRAULIC DRIVE UNIT
No. Qty Part # Description
1 1 171-1.59-1 Motor, Hydraulic
2 1 165-00H010 Pulley
3 1 463947 Hub, Split Tapered
4 1 168-12-325 Belt
5 1 461146 Relay, 12V
6 1 174-PS-010 Switch, Swing Sense 625 psi NO
7 1 12-SD-407A Compressor
8 1 550867 Fan Group
9 1 101-HD8017 Hose Assy, Refrig. #8 Discharge (w/ (2) #8 O-rings (404981))
10 1 463734 Coil, Condenser
11 1 101-HD6022 Hose Assy, Refrig. #6 CD to RD (w/ (2) #6 O-rings (405011)
12 1 82-00-001 Receiver-Drier
13 1 403081 Binary Switch
14 1 465467 Wire Harness (not shown)

TXCR325.doc 18 1/31/2008
 12-SD-407A AC COMPRESSOR
No. Qty Part No. Description
1,2,3 1 122-SD4004 Clutch Assy, 12V
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. Do not torque the dowels so they deform the clutch plate!

550867 CLUTCH FAN ASSEMBLY

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

TXCR325.doc 19 1/31/2008
 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 OUTSIDE AIR FILTER

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”

TXCR325.doc 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.

TXCR325.doc 21 1/31/2008
Notes:

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TXCR325.doc 22 1/31/2008
TXCR325.doc 23 1/31/2008
 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

TXCR325.doc 24 1/31/2008