Sunteți pe pagina 1din 26

19/10/2017 RT200-600 Series | Kenway Engineering

507.238.9051
507.238.9998 fax

RT200-600 SERIES MANUAL


RT200-600 Series
TEREX CRANES T (UPPER) & RT SERIES: 12 VOLT AC & OIL HEAT

http://www.kenwayengineering.com/support/manuals/rt200-600-series 1/26
19/10/2017 RT200-600 Series | Kenway Engineering

Table of Contents

http://www.kenwayengineering.com/support/manuals/rt200-600-series 2/26
19/10/2017 RT200-600 Series | Kenway Engineering

Third Version Produced Model 9027


Maintenance
Air Conditioning / Oil Heat Operation
Hydraulic Oil Heat Unit Initial Starting Instructions
Heater Operating Range: Upper systems, T200/T300/T500/T700, RT
Wire Schematic: Upper system, T200/T300/T500/T700/RT
Belt Tensioning For Hydrauling Heat and AC Units
Recommended Guidelines for Servicing
Options/Features: Model 9027 Hydraulic Drive Heat and Compressor/Condenser
Replacement Parts: Model 9027 17-9027-11
Replacement Parts: Blower System VWM 2AOH
Options/Features: Model 321 Vertical / Floor Mount Blower
Replacement Parts: Blower 02-VW72-03
Replacement Parts: Hose Kit 10-LR-005
Replacement Parts: Filter Kit 22-01-001
NOTICE: Hydraulic Motor Vendor Change

http://www.kenwayengineering.com/support/manuals/rt200-600-series 3/26
19/10/2017 RT200-600 Series | Kenway Engineering

Third Version Produced Model 9027

Compact

Has smaller foot print than previous version. The heat developer is built into the heat pump which gives the system greater reliability and heat production at low idle.
The heat developer uses the machines own hydraulic oil eliminating the need to remember to replace the oil periodically reducing the chance of pump failure and
becomes less maintenance intensive. The condenser is custom built to be an iatrical part of the system allowing for best cooling capability, along with a condenser
fan requiring zero electrical power to operate. All stainless steel housing provides for a lasting and corrosion free finish

Control

Same simple controls as the first two revisions.

http://www.kenwayengineering.com/support/manuals/rt200-600-series 4/26
19/10/2017 RT200-600 Series | Kenway Engineering

Maintenance
Filters
Check and clean the inside recirculation filter once a week. This filter is very important to keep in good shape. Without it the blower system would not able to pass
air over the coils thus reducing its ability to cool or heat.

If Equipped
Clean the outside paper filter daily or as needed. This filter allows outside fresh air into the cab. Keeping this filter clean will greatly enhance the cab
environment.

Condenser
Clean out with air or water daily or as needed to remove dirt and debris from building up. Take special care not to damage coil fins. Inspect hoses and coil for wear
or oil build-up since this may indicate a refrigerant leak in the system.

Compressor / Belt & Clutch


Check the belts for tightness as often as you would for any of the other belts on the machine. When replacing worn belts spin the compressor pulley to check for
rough spots or a loose clutch. If either of these occurs, a service on the part should be performed as soon as possible.

Always
Look for signs of leaks or wear on the hoses or other components. Move or relocate hoses that are rubbing or look as though they will be a problem in the future.

Listen for abnormal sounds from the electric motors, compressor or other parts of the heater air conditioner system. These could be signs of needed service.

Respond to early service warnings. It will help avoid bigger and more costly problems in the future.

http://www.kenwayengineering.com/support/manuals/rt200-600-series 5/26
19/10/2017 RT200-600 Series | Kenway Engineering

Air Conditioning / Oil Heat Operation


To operate the air conditioner/oil heater, use the following procedures:

A) Air Conditioning Mode:

1. Start the machine and rotate the fan control to high, medium, or low speed.
2. Set the master toggle switch to the a/c mode.
3. Rotate the air conditioning thermostat to a desired setting. Rotating the thermostat clockwise will increase cooling.

B) Oil Heat Mode:

1. Start the machine and rotate the fan control to high, medium, or low speed.
2. Set the master toggle switch to the heat mode.
3. Rotate the heat thermostat to a desired setting. Rotating the thermostat clockwise will increase heating.
4. Increase the machine idle up to about 1000 rpm, or until there is adequate heat, and then return to low idle. If there is not adequate heating at low idle, increase
the engine rpm until adequate heat is achieved.

http://www.kenwayengineering.com/support/manuals/rt200-600-series 6/26
19/10/2017 RT200-600 Series | Kenway Engineering

Hydraulic Oil Heat Unit Initial Starting Instructions


Before starting the machine, turn off the heat mode at the blower unit and make sure the toggle switch on the hydraulic unit if in the OFF position.
Start the machine and allow to run for approximately 30 minutes with only the hydraulic motor turning. This allows the hydraulic oil to fill oil the heater circuit.
Check the direction of the motor rotation, it must be CCW as viewed from the port end of motor. If incorrect, switch supply and return lines around on the
hydraulic motor.
Check to see if the hydraulic oil has filled the heat circuit. A Philips screw on top of the proportional relief valve acts as a bleed port. Back out the screw two to
four rotations to allow any trapped air to escape. Note: The pump doesnt have to be turning, the case drain from the rotating motor should provide enough
pressure to fill heat circuit.
Turn on the heater inside the cab by turning the thermostat to maximum and flipping the mode switch to heat. Note: Operating the pump prior to filling the circuit
with oil can cause damage to the pump.
On the hydraulic unit, flip the heat clutch toggle switch to ON. Listen for the pitch of the pump to increase. If it doesnt, turn the toggle switch to Off and check
the electrical circuits, check pump rotation, and check oil fill.
Operate the system for at least fifteen minutes, check that the pump speed, motor speed and the hydraulic pressures fall within parameters as indicated on the
Hydraulic Schematic.

WARNING
Only qualified hydraulic repair technicians, fully aware of the hazards should perform the above retrofit.

Note: Kenway does not intend for these instructions to be fully encompassing.

http://www.kenwayengineering.com/support/manuals/rt200-600-series 7/26
19/10/2017 RT200-600 Series | Kenway Engineering

Heater Operating Range: Upper systems, T200/T300/T500/T700, RT

http://www.kenwayengineering.com/support/manuals/rt200-600-series 8/26
19/10/2017 RT200-600 Series | Kenway Engineering

http://www.kenwayengineering.com/support/manuals/rt200-600-series 9/26
19/10/2017 RT200-600 Series | Kenway Engineering

Wire Schematic: Upper system, T200/T300/T500/T700/RT

http://www.kenwayengineering.com/support/manuals/rt200-600-series 10/26
19/10/2017 RT200-600 Series | Kenway Engineering

Belt Tensioning For Hydrauling Heat and AC Units

http://www.kenwayengineering.com/support/manuals/rt200-600-series 11/26
19/10/2017 RT200-600 Series | Kenway Engineering

Recommended Guidelines for Servicing


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, 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.

http://www.kenwayengineering.com/support/manuals/rt200-600-series 12/26
19/10/2017 RT200-600 Series | Kenway Engineering

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 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

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 remove some refrigerant to restore the discharge pressure reading.

http://www.kenwayengineering.com/support/manuals/rt200-600-series 13/26
19/10/2017 RT200-600 Series | Kenway Engineering

If the sight glass doesnt 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.

http://www.kenwayengineering.com/support/manuals/rt200-600-series 14/26
19/10/2017 RT200-600 Series | Kenway Engineering

Options/Features: Model 9027 Hydraulic Drive Heat and Compressor/Condenser


OPTIONS:

Air Conditioning (R134a) and/or Hydraulic Oil Heat


12 Volt or 24 Volt
Gallon configurations are 6-10, 11-15, 16-20, 21-25, 26-30, 31-35 GPM
Brackets for vertical mounting

FEATURES:

Housing is made of 7 gauge through 3/8 thick steel with black powder coated finish
Shielding is made of 18 gauge stainless steel
Single mounting style with standard horizontal positioning of the whole unit
Uses belt drive system with bolt adjustment of belt tightening
Uses all around shielding from moving parts
Air Conditioning Unit includes compressor, condenser, drier, and binary switch
Hydraulic Unit includes pump, motor, relief valve, and heat developer block
Connections on unit: A/C = #6 (Drier) and #10 (Compressor) male O-ring, Hydraulic
Motor = #12 female Boss O-ring (2), Hydraulic Heat = #8 JIC male (2)
Air Flow = 1200 CFM
Weight = 140 LBS (A/C and Heat unit), 104 LBS (A/C only)

http://www.kenwayengineering.com/support/manuals/rt200-600-series 15/26
19/10/2017 RT200-600 Series | Kenway Engineering

IMPORTANT!!! Kenway is not responsible for the vehicle hydraulic system modifications. Use only a trained hydraulic technician.

http://www.kenwayengineering.com/support/manuals/rt200-600-series 16/26
19/10/2017 RT200-600 Series | Kenway Engineering

http://www.kenwayengineering.com/support/manuals/rt200-600-series 17/26
19/10/2017 RT200-600 Series | Kenway Engineering

Replacement Parts: Model 9027 17-9027-11

http://www.kenwayengineering.com/support/manuals/rt200-600-series 18/26
19/10/2017 RT200-600 Series | Kenway Engineering

http://www.kenwayengineering.com/support/manuals/rt200-600-series 19/26
19/10/2017 RT200-600 Series | Kenway Engineering

http://www.kenwayengineering.com/support/manuals/rt200-600-series 20/26
19/10/2017 RT200-600 Series | Kenway Engineering

Replacement Parts: Blower System VWM 2AOH

http://www.kenwayengineering.com/support/manuals/rt200-600-series 21/26
19/10/2017 RT200-600 Series | Kenway Engineering

http://www.kenwayengineering.com/support/manuals/rt200-600-series 22/26
19/10/2017 RT200-600 Series | Kenway Engineering

Options/Features: Model 321 Vertical / Floor Mount Blower


OPTIONS:

AC Only, Heat Only-Water or Oil, or Combo


12 Volt or 24 Volt
Hose adapter ports for output of air for defrost or floor.
Fresh Air input.
Remote mounting of switches.

FEATURES:

Housing is made of 16 gauge steel with black powder coated finish.


Filtered recirculated air.
Five adjustable flow and directional louvers.
Rotary controls for AC, Heat and 3-speed fan.
Block type expansion valve with easy hose installation.
Side cover. (not shown)
Connections: A/C = #6 and #10 Male O-ring, Heat = #8 male JIC (Oil), 5/8 ID Hose (Water)
Capacity: Heating = 30,000 BTU/H (Water)/ 20,000 BTU/H (Oil), Cooling = 21,000 BTU/H, Air Flow

http://www.kenwayengineering.com/support/manuals/rt200-600-series 23/26
19/10/2017 RT200-600 Series | Kenway Engineering

http://www.kenwayengineering.com/support/manuals/rt200-600-series 24/26
19/10/2017 RT200-600 Series | Kenway Engineering

Replacement Parts: Blower 02-VW72-03

http://www.kenwayengineering.com/support/manuals/rt200-600-series 25/26
19/10/2017 RT200-600 Series | Kenway Engineering

Replacement Parts: Hose Kit 10-LR-005

http://www.kenwayengineering.com/support/manuals/rt200-600-series 26/26