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Kenway TXCR326
Kenway TXCR326
OWNER’S MANUAL
TXCR326/H/A
A/C & Oil Heat System
INSTALL/INSERVICE DATE:_________________
SERIAL #:__________________________________
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)
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.
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.
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.
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.
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.
Manual
Automatic
D Remove and
inspect Fresh X
X
X
Clean and damage free.
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
y Check Cab
Blower Motor
X X Systems doesn't power up. Check fuses.
e worn or damaged.
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
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.
Check compressor mount components for
tightness/ check clutch air gap for
minimum clearance of .016" and
uniformity.
l X Unusual noise-AC not cooling.
Worn or damaged clutch or compressor.
Discontinue operation until serviced.
Oily dirt accumulating behind
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.
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.
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
The Electrical Schematic follows.
Connector “D”
D-1 C AC
D-2 P SS
D-3 PH
D-4 CTR O
D-5 CTR I
D-6 CTR G
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.
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.
• This will return most of the refrigerant oil back to the compressor.
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:
• 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.
OPTIONAL-FILL
THIS LINE FIRST
TO FILL HEAT
COIL FROM
BOTTOM UP.
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.
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).
HIGH PRESSURE
PORT (DH)
Note: Port maybe found
on back of pump.
LOW
PRESSURE
PORT (DL)
TENSIONER
BOLT
TENSIONER
BOLT
INLET
PORT
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)
Visual Check:
• Check for hydraulic oil leaks.
• Broken, discolored or disconnected wiring.
• Pinched hydraulic lines.
• Check tension on drive belts.
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.
• 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.
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.
Set Master
Power & Fan
Speed "On"
Set to "Heat
Mode"
NO
End
DL PORT DH PORT
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.
DL PORT DH PORT
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.
DL PORT DH PORT
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.
DL PORT DH PORT
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.
DL PORT DH PORT
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.
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.
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.
DL PORT DH PORT
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.
DL PORT DH PORT
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.
DH PORT
AC System:
(Note: AC compressors supplied with Kenway systems have sufficient oil in them for the entire AC
system)
• www.macsw.com
• www.sae.org
• www.aircondition.com
• www.ashrae.org
AC Book:
-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
-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
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Phone: 507-238-9051
Fax: 507-238-9998