Академический Документы
Профессиональный Документы
Культура Документы
TXCR325/A/B
(Model VW7 and 17-9057)
MACHINE MODEL:_____________________
MACHINE SERIAL #:___________________
BLOWER SERIAL #:____________________
HYDRAULIC DRIVE SERIAL #:__________
INSTALL/INSERVICE DATE:_____________
TXCR325.doc
1/31/2008
TXCR325.doc
1/31/2008
APPLICATION
TXCR325 USED ON T/RT500, 600,700
TXCR325A USED ON RT1120
TXCR325B USED ON T/RT200, 300
KENWAY AC SYSTEM
Overview:
The Kenway AC System is a standard automotive thermo-expansion valve system. It
differs in that it is not driven by a gas or diesel engine but is driven by a hydraulic motor.
If the hydraulic motor is functioning correctly any qualified automotive AC technician
should be able to service the AC side of our unit.
Below left is a typical cab unit. It consists of a heat exchanges and a blower with motor.
The heat exchanger is the AC systems evaporator coil. Outside air is filtered by a paper
filter located in the housing on the back of the cab. Inside air is filtered by a reusable
foam filter located on the front bottom of the blower unit.
On the right is the MD 9057 Hydraulic Drive Unit. Its main components are: Hydraulic
drive motor; AC compressor, AC Condenser heat exchanger and the Receiver-Drier.
TXCR325.doc
1/31/2008
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
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
1/31/2008
Maintenance:
Check
Check/
Inspection
point
Remove
Recirculation
Air filter.
D
a
i
l
y
Remove and
inspect Fresh
Air filter.
A
I
r
H
e
a
t
Observation
Action/Remedy
X
X
X
X
Re-install.
Blow clean with low pressure air
gun or wash with soap and water.
X
X
Re-install
Note: If both fresh air and recirculation filters are excessively dirty, check the evaporator and heater
coil for dirt contamination and clean with warm water and soap to get optimum AC and heat
performance.
Check Cab
Blower Motor
TXCR325.doc
No Action necessary.
Check fuses.
No fan speeds.
Excessive noise.
1/31/2008
Maintenance:
Check
W
e
e
k
l
y
Check/
Inspection
point
Check
Compressor
Or
Heat Pump
Drive Belt
A
I
r
H
e
a
t
Observation
Action/Remedy
No Action necessary.
X
Check
condition of
Condenser
Assembly.
Check
condition of AC
and Heater
Hoses
TXCR325.doc
No Action necessary.
Troubleshoot electrical circuit. Check
condenser ground, Relay, Fuse.
Fan worn out. Replace.
Clean with air, soap and water, or coil
comb. Do not use sharp tools or bend the
fins.
Have AC system repaired immediately.
Delays will result in more costly repair
later on.
No Action necessary.
Worn or abraded.
Loose
Oil/dirt accumulation.
1/31/2008
Maintenance:
Check
M
o
n
t
h
l
y
Check/
Inspection
point
Air Conditioner
Clutch
A
I
r
H
e
a
t
Oil heat
Air Conditioner
Compressor
TXCR325.doc
No Action necessary.
Check
Receiver Drier
Sight Glass
with machine
operating in
max. AC mode.
Action/Remedy
X
X
Observation
1/31/2008
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:
Precaution:
Digital Multimeter
TXCR325.doc
1/31/2008
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:
TXCR325.doc
10
1/31/2008
TheElectricalSchematicfollows.
TXCR325.doc
11
1/31/2008
ITEM
1
2
3
4
5
6
11
16
17
PART #
400093-A
78B-12010
463710-A
461904
403081
122-SD4004
174-PS-010
461146
463509
DESCRIPTION
SWITCH, MASTER PWR & FAN SPEED
BLOWER, W/ 3-SPD RES.
SWITCH, MODE-ROTARY
SWITCH, AC THERMOSTAT-FIXED
SWITCH, AC BINARY PRESSURE
CLUTCH, AC COMPRESSOR
SWITCH, SWING SENSE PRESSURE (NO)
RELAY
SWITCH, LIGHTED ROCKER
END
TXCR325.doc
12
1/31/2008
Visual Check:
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
Does the cab unit blow air? Check fuse and electrical connections to the controls
and blower system.
The electrical schematic appears on page 11.
If a problem cannot be solved feel free to contact: Kenway Engineering, Inc at 507-2389051 between the hours of 8:00am to 4:30 pm CST. Please have the following
information:
Machine Model, Serial #, and Hour meter reading
Kenway Serial #s from the blower unit and hydraulic drive unit (see the following
breakdowns for serial # location)
TXCR325.doc
13
1/31/2008
Inspection
Interval
Remove
Recirculating Air
filter.
Daily/
Application
Dependent
Remove and
inspect Fresh Air
filter.
Daily/
Application
Dependent
Observation
Action/Remedy
Re-install.
Blow clean with low pressure air gun
or wash with soap and water.
Replace with new.
Re-install
Blow clean with low pressure air
gun.
Replace with new.
Check Cab
Controls.
Note: If both fresh air and recirc. filters are excessively dirty, check the
evaporator coil for dirt contamination and clean with warm water and
soap to get optimum AC performance.
Follow operation instructions at the
beginning of this manual.
Monthly
System powers down and up.
Check blower
speeds
No blower operation
No fan speeds.
Check Compressor
Drive Belt
Turn on AC and
check compressor
clutch and
compressor
operation.
Weekly
Monthly
Check fuses.
No Action necessary.
Check blower wiring and blower
operation.
Check blower wiring and blower
operation.
Excessive noise.
No Action necessary.
Oil Slicked/glazed/ or
excessively worn or damaged.
No unusual noise. No clutch
slippage: sharp engagement and
release. No oily dirt
accumulation on fittings or seals.
Good cooling.
No unusual noise. No clutch
slippage: sharp engagement and
release. No oily dirt
accumulation on fittings or seals.
Poor cooling.
No engagement. AC Mode "On";
No or low voltage.
Clutch slips, Voltage across
clutch coil above 9 V. (22V)
TXCR325.doc
No Action necessary.
14
1/31/2008
Check condition of
Condenser
Assembly.
Weekly
Check condition of
AC and Heater
Hoses
Weekly
Worn or abraded.
Loose
Oil/dirt accumulation.
Check Receiver
Drier Sight Glass
with machine
operating in max.
AC mode.
TXCR325.doc
15
No Action necessary.
Troubleshoot electrical circuit.
Check condenser ground, Relay,
Fuse.
Fan/s worn out. Replace.
Clean with air, soap and water, or
coil comb. Do not use sharp tools or
bend the fins.
Have AC system repaired
immediately. Delays will result in
more costly repair later on.
No Action necessary.
If AC hose have serviced. If heater
hose determine cause, rectify
problem and replace hose.
Re-secure with hose clamps or
nylon ties.
Indicates refrigerant and oil leak.
Have system promptly serviced.
No action necessary.
If over 80F, no action necessary. If
not may indicate slightly low charge
or refrigerant contamination. Have
serviced soon.
Probable low refrigerant charge.
Service AC system immediately.
1/31/2008
CASE
DRAIN
TXCR325.doc
INLET
PORT
16
TENSIONER
BOLT
1/31/2008
SERVICE PARTS
Qty
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
1
2
1
2
1
4
1
1
2
1
1
1
1
1
Part No.
400093-A
463710-A
461236
463509
461983
80-RCF009
463402
78B-12010
461904
404981
461232
81-XEO010
462305
463504
465465
TXCR325.doc
Description
Switch, Master/Fan w/ Off (w/ 300701 Jam nut)
Switch, Mode (w/ 300701 Jam nut)
Knob w/ Set Screw
Switch, Rocker Lighted
Thumb Screw
Filter, Recirculated Air
Louver
Blower & Motor Assy
Switch, A/C Thermostat
O-ring #8
Coil, Evaporator
Valve, Expansion
Drain Tube
Drain Tube Valve
Wire Harness (not shown)
17
1/31/2008
Qty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
TXCR325.doc
Part #
171-1.59-1
165-00H010
463947
168-12-325
461146
174-PS-010
12-SD-407A
550867
101-HD8017
463734
101-HD6022
82-00-001
403081
465467
Description
Motor, Hydraulic
Pulley
Hub, Split Tapered
Belt
Relay, 12V
Switch, Swing Sense 625 psi NO
Compressor
Fan Group
Hose Assy, Refrig. #8 Discharge (w/ (2) #8 O-rings (404981))
Coil, Condenser
Hose Assy, Refrig. #6 CD to RD (w/ (2) #6 O-rings (405011)
Receiver-Drier
Binary Switch
Wire Harness (not shown)
18
1/31/2008
12-SD-407A AC COMPRESSOR
No. Qty Part No.
Description
1,2,3
122-SD4004
461976
Note: Use high strength thread-locker when installing shaft extension and threaded dowels on to the compressor
clutch. Do not torque the dowels so they deform the clutch plate!
1
3
1
1
3
1
4
1
4
4
462659
463435
462660
462721
TXCR325.doc
Description
Shaft Extension
Threaded Dowel
Fan Spacer Hub
Blade, 14
Washer, Flat
HHCS 1/2" NF x 1 1/4
HHCS 5/16 NC x 3/4"
Washer Lock
Washer 5/16 Lock
Washer 5/16 Flat
19
1/31/2008
Qty
RT/T500,600,700
1
1
1
1
1
1
1
1
1
RT1120
RT/T200,300
Part #
Description
101-TX6017
101-LR0004
101-HD6025
101-TX6017
101-LR0004
101-HD6028
101-TX6020
101-TX0020
101-HD6029
Qty
1
2
3
4
5
6
1
2
1
2
2
1
TXCR325.doc
Part #
Description
221-001
463428
221-002
463713
461987
80-OSP010
Base Filter
Retainer Nut
Cover, Filter
Washer
Thumb screw
Filter, Paper 1 X 6 X 9 3/8
20
1/31/2008
Appendix:
(Note: AC compressors supplied with Kenway systems have sufficient oil in them for the entire AC
system)
TXCR325:
www.macsw.com
www.sae.org
www.aircondition.com
www.ashrae.org
AC Book:
Upgrade Note:
This AC Only System is Oil Heat Upgradable. Contact Kenway Engineering for additional
information.
TXCR325.doc
21
1/31/2008
Notes:
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
______________________________________________________________________________________
TXCR325.doc
22
1/31/2008
TXCR325.doc
23
1/31/2008
507-238-9998
sales@kenwayengineering.com
* AIR CONDITIONERS * ENGINE MOUNT KIT
TXCR325.doc
24
1/31/2008