TXCR406 Installation Instructions

Teardown:

1. Recover refrigerant from AC system if present.

2. Disconnect and remove Kenway hydraulic drive
unit, if present.
3. Remove seat.
4. Disconnect and remove Kenway blower unit and
controls, if present.
5. Disconnect and remove Propane heater and
controls, if present.
6. Remove shelf unit from back of cab. Windshield
washer fluid bottle will need to be temporarily
removed. FIGURE 1 Cab is sectioned in half

7. Remove outside air filter, if present.

Cab modifications:

1. Install Z bracket from new blower unit in back of

cab. Position bracket as shown and center
between the sides. Mark or center punch the
mounting holes (4x) and drill out with a sharp
7/32" bit. Supplied fasteners are self tapping 1/4-
20 thread. Figure 2
2. The back of the cab needs modification for the
fresh air intake. Use the fresh air filter adapter
plate from the new blower kit as a template. The
FIGURE 2
existing filter mounting holes may or may not
work. Mark the holes for the fresh air intake, for
the wire harness and if necessary the filter
mounting. The fresh air intake and wire harness
holes need to be cut oversized. Actual mounting
is through the adapter plate. If there is a bump
out for the propane heater make sure to allow
enough room for so the operator can access the
cover knob on the fresh air filter. (Figure 3)
3. Remove windshield and front dash access panel.
Install the 3-wire harness from the kit. Two of the FIGURE 3

wires connect into the machine harness on the

floor to the right of the seat position. The wire
marked "PWR" goes to the wire labeled 47 and
the "GRD" goes to the wore marked "16". The
third wire is for a headlight signal. Its needs to be

txcr406 aftermarket installation instructions    3/18/2010 
 fished up through the right hand console up to the
dash. A terminal doubler on the harness goes on the
second dash lamp from the right (labeled 52). Note:
older machines may require additional wiring for the
PWR and GRD connections.
4. Remove 7.5 amp fuse from "Heat/AC" (CR5) and
replace with 20 amp fuse from "Heater" (CR13). Note:
older machine may differ.
5. Install the hose splicer and additional duct hose from
the kit onto the existing dash duct hose. FIGURE 4
6. Install the propane heater vent cover provided as
necessary.

Cab Unit Installation:

1. Install the lower shelf panel. Route the wiring and lower
duct hose to the right side of the cab. (Figure 5)
2. Route the longest branch of the wire harness up into
the right switch panel and install the control plate and
keypad.
3. The shortest branch of the harness marked "HYD" goes
to the hydraulic unit. Poke this connector out the
rectangular hole in the back. The other marked "BLWR"
goes to the blower unit and will be connected when the FIGURE 5
blower unit is in place.
4. Remove the cover from the blower unit. Install the main
unit in the cab. Route the two drain tubes through the
hole in the floor at the base of the lower shelf panel.
Route the duct hose from the bottom of the unit through
the fresh air cutout at the back of the cab. The unit is
secured with three screw going into the Z-bracket and
two into the lower shelf panel. (Figure 6)
5. Connect the dash duct hose and the hose from the
lower shelf unit to the hose adapters under the blower
plate.

FIGURE 6

txcr406 aftermarket installation instructions    3/18/2010 
 

Hydraulic Drive Unit Installation:

1. Bolt the drive mounting brackets to the superstructure behind the

cab. A number of bolts pattern are available. Use the holes which
get the drive unit mounting hole to 17.5". Leave the bolts loose.
(Figure 7)
2. Remove the 3/8 mounting hardware from the hydraulic drive unit and
save. Hoist the hydraulic drive unit on to the mount brackets and use
the 3/8" hardware to bolt it down. (Figure 8) FIGURE 7
3. Tighten the mount bracket hardware to the
superstructure.

Hose Installation:

1. Install the hose grommets into the back of the cab. There
maybe four or five knocks. Only four need to be removed.
2. Install the two heater lines. Leave fittings loose.(Figure 9)
3. Install the two AC Lines. Lubricate the o-rings with a light oil
preferably with refrigerant oil prior to assembly. (Figure 10)
4. Align the hoses so they do not kink or bend excessively. FIGURE 8
Tighten both ends of the four hose assemblies
and secure the middle with the tie wraps and
hose clamps provided.
5. Install the case drain hose. (Figure 11)
6. Install the high pressure hoses. These hoses are available
from Kenway or Terex. If this is an AC or AC /Heat upgrade
installation the existing high pressure lines will work.

Warning: Do not start

the machine until the
Oil Heat Circuit has
FIGURE 9
been pre-charged.

Case
drain

Outlet

Inlet
FIGURE 11 FIGURE 10

txcr406 aftermarket installation instructions    3/18/2010 
 

Oil Heat Circuit Charging:  

1. The oil heat circuit needs to be pre‐charged with the same 
hydraulic oil the machine has prior to machine startup. Failure to 
perform this could damage the pump and other components. 
2. The factory method pressurizes the main hydraulic tank. and puts 
a air bleeder and hose on the "DH" port of the pump assembly.   OLS 
Oil fills the circuit through the case drain hose. When a solid  Manifold 
Port 
stream of oil is discharged from the air bleeder hose for a 
minimum of 3 minutes the circuit is full. 
3. Remove the cover of the hydraulic unit. Remove the case drain 
hose and fitting from the top of the oil level switch manifold. Also,  DL Port
remove the gauge port adapter located at DL on the heat 
FIGURE 12
manifold block. 
4. Fill the oil at the oil level switch manifold, fill slowly so as not to 
trap any air. When the oil level at the DL port reaches the top and 
air stops bubbling out., replace the port adapter and continue 
filling until it reaches the top of the oil level switch manifold. 

AC Refrigerant Charging: 

Note:  

1. Follow standard automotive charging procedures. If vapor 
charging make sure the oil circuit has been charged and the 
control and electrical performed prior to starting the engine. 
2. Refrigerant charge is:  2.50? lbs ofR‐134a. With a new system 
there is no need to add refrigerant oil. 

Control and Diagnostic Checks: 

1. With the Heater circuit and AC charged.  Check and fix any leaks 
of refrigerant and hydraulic oil. 
2. Place the blower unit cover on the blower unit and turn on the 
key but do not start the engine. 
3. The keypad will blink the 3,4,7,8 keys. If you have a T/RT 200,300 
or 400 press the 3 and 4 key simultaneously. If you have a T/RT 
500,600,700,1100 press  the 7 and 8 key simultaneously. 
4. The control should be in Standby mode with all LEDs off. If not 
press the 2 button. Perform the input diagnostic check as shown 
in the Owner's Manual. Correct any issues or contact Kenway 
FIGURE 13
Engineering for advice. (Figure 13) 

txcr406 aftermarket installation instructions    3/18/2010 
 5. Take the control out of standby mode by pressing 2. Check for three fan speeds. 

Functional Checks: 

1. AC: With the controller set and diagnostic check performed, 
start the machine and set the keypad to high fan, AC mode, 
and the minimum temperature set‐point. The AC clutch will 
engage unless there are adverse weather conditions 
preventing it. Turn off the engine  and use standard  leak 
checking procedures check for refrigerant and for hydraulic 
leaks. 
2. Heat: Place a 5000 psi test gage on the DH port and a 200 psi 
test gage on the DL port. Turn on the engine and set the 
keypad to heat mode and lowest temperature setting.  
3. The heat pump clutch may not engage. Turn up the 
temperature set‐point  until it does. 
4. If the gages jump erratically there is too much air in the heat 
circuit. Immediately turn off the heater and the engine.  
Check the quality of the oil in the heat circuit. If it is very 
foamy, the oil should be purged and recharged. Slight 
amounts of air can be removed by operating  in AC mode. 
5. If the gages are steady, turn up the temperature set‐point on 
the control. 
6. Remove blower cover and perform a final leak check. 
7. Replace cover and bolt it down. 
8. Replace seat, covers, windshield s, etc. 

txcr406 aftermarket installation instructions    3/18/2010