YILKAR YK 155 MB Installation Instruction
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YILKAR YK 155 MB Installation Instruction

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Installation Instruction
YK 155 MB
SSH.MT.01.06 - TR
The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023
YILKAR
EN

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  • Page 1 YILKAR Installation Instruction YK 155 MB SSH.MT.01.06 - TR The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023...
  • Page 2 07.02.2023 H.Kübra Şahin First publication REVISION NO PUBLISH DATE REVISING PERSON REASON FOR REVISION SSH.MT.01.06 - TR The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023...

  • Page 3: Table Of Contents

    3.2 General Description................... 7 4.Installation of Yılkar YK 140 MB................9 4.1 General Assembly Diagram ..............9 4.2 YK 155 MB U Connection Profiles Mounting ..........10 4.3 Monoblock Unit Mounting ................ 12 4.3.1 YK 155 MB Unit Dimensions ............12 4.3.2 Unit Positioning and Roof Mounting ...........
  • Page 4 5. Commissioning the Air Conditioner ..............31 6. Spare Parts ......................32 6.1. Condenser Spare Parts ................6.2. Evaporator Spare Parts ................6.3. Other Spare Parts ..................7. Usage and Maintenance Recommendations ............. SSH.MT.01.06 - TR The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023...

  • Page 5: Introduction

    1. Introduction This instruction is part of the YK 155 MB air conditioner. All necessary information for installation is explained and includes information on safe use of the device. Please read this installation instruction carefully in order to fully install Yılkar air conditioner.

  • Page 6: Warranty And Liability

    1.1 Warranty and Liability Warranty conditions YILKAR assures its customers that the products they buy are manufactured in accordance with today's technology and without any errors. All YILKAR Authorized Dealers are obliged to carry out warranty transactions regardless of which authorized dealer the vehicle is sold by.

  • Page 7: Security And Legal Regulations

    1.2 Security and Legal Regulations Read this service manual carefully before operating your YK 155 MB model roof type air conditioner. In case of problems that may occur as a result of improper use conditions, the warranty is canceled and compensation claims are not taken into account.

  • Page 8: Definition And Technical Information

    2. Definition and Technical Information 2.1 What is YK 155 MB? YK 155 MB is an innovative designed air conditioning device developed for air conditioning minibuses up to 17 seats. The easy-to-install unit includes a condenser and an evaporator. These units must be mounted on the roof of the vehicle and connected to the compressor via hoses circulating R134a refrigerant.

  • Page 9: Yk 155 Mb Technical Data

    2.3 YK 155 MB Technical Data Roof Type Air Conditioning Unit YK 155 MB Compressor SD7-TM16-TM21 10-15,5 kW Cooling Power (34121 - 52888 BTU/h) (8598 - 13327 kcal/sa) Oil Type PAG 100 yağ Oil Amount 250 ccm Refrigerant / Amount R 134 a / 1850 ±...

  • Page 10: Overview

    3. Overview 3.1 YK 155 MB Overview 3.1.1. YILKAR Monoblock Un t MONOBLOCK UNIT - YK 155 MB 1 Piece 310.01.YK155.01 MONOBLOCK GROUP - YK 150 MB 1 Piece 500.22.YK155.02 AIR SUCTION GRILL COMPLETE 1 Piece 501.24.HEIPL.09 GRAY - YILKAR - 65X22...

  • Page 11: General Description

    3.2 General Description Fiber Cover The cover made of fiber material is mounted on the condenser unit on the vehicle roof and acts as a condenser protection. Condenser It is the air conditioning system element in which the high pressure R134a refrigerant gas taken from the compressor in the condenser air conditioning system becomes liquid by giving heat to the environment.
  • Page 12 Compressor It is the pump of the system that compresses the R134a air conditioner gas in the compressor air conditioning system and increases its pressure. Relay Board The relay switches on and off the current path with the help of current and voltage values in the air conditioning system.

  • Page 13: Installation Of Yılkar Yk 140 Mb

    4. Installation of Yılkar YK 155 MB 4.1 General Assembly Diagram KONDENSER VALF KOMPRESÖR EVAPORATÖR Low Pressure L ne H gh Pressure L ne In the above assembly diagram, the flow direction of the R134a refrigerant and the low- high pressure zones are shown on the components connected to each other by hoses in...

  • Page 14: Yk 155 Mb U Connection Profiles Mounting

    4.2 YK 155 MB U Connection Profiles Mounting Connection plates are the first mounting parts used to fix the condenser and evaporator to the vehicle roof and to each other. Remove the fiber cover just before this procedure. Assembly Step 1: First of all, cut the U-connection profiles to the dimensions suitable for the roof of your vehicle.
  • Page 15 Assembly Step 4: The position of the U connection profiles to be used for the monoblock unit should be marked on the roof in the vehicle as shown below, and it should be mounted to the roof with a drill-tipped trapezoidal M5x25 screw. 24 connection screws are used for this connection.

  • Page 16: Monoblock Unit Mounting

    4.3 Monoblock Unit Mounting 4.3.1 YK 155 MB Un t D mens ons 1960 1280 4.3.2 Un t Pos t on ng and Roof Mount ng To fix the air conditioner, 12 holes must be drilled in the roof of the vehicle.
  • Page 17 Assembly Step 6: For YK 155 MB, mark the places to be drilled, the details of which are given in the technical drawing, on the vehicle by referring to the fiber cover dimensions. Drill the marked places with suitable tools and equipment.
  • Page 18 Assembly Step 7: Insulate the bottom of the monoblock unit on the roof of the vehicle with 10 mm PE ARMAFLEX according to the given dimensions. ARMAFLEX 1150 MONOBLOCK UNIT BOTTOM VIEW...
  • Page 19 Assembly Step 8: Mount the mounting wedges used for vibration damping on the vehicle roof to the drilled holes and insulate with SIMSON ISR 70-03 white mastic. Assembly Step 9: Assemble the hose grommet to the hole drilled for the grommet on the vehicle roof and insulate it with SIMSON ISR 70-03 white mastic.
  • Page 20 Assembly Step 11: Mount the evaporator part of the monoblock unit to the vehicle roof. Insert the bolts from the bottom of the roof into the indicated connection holes and mount them with M10 washers and nuts from the top. Bolt Connection M10 Nut M10 Washer...
  • Page 21 Assembly Step 12: After applying silicone to the wedges, apply SIMSON ISR 70-03 white sealant around the area where the evaporator unit will be placed. Attention should be paid to the sealing of the area between the condenser and the evaporator and it should be ensured that this area does not leak.
  • Page 22 MONOBLOCK UNIT TOP VİEW...

  • Page 23: Hoses And Fitting

    4.4 Hoses and Fitting The air conditioning system is sent by the factory with a pressure of 20 bar inside. 5/8x18 UNF INION While removing the existing plugs at the connection points, it should be checked whether there is Nitrogen gas in it. 5/8x18 unf inion is used for additional evaporator connection.

  • Page 24: Air Conditioner Hoses And Fitting Connections

    4.4.1 A r Cond t oner Hose and F tt ng Connect ons 4.4.1.1. A r Cond t oner Hose The hose types in compliance with SAE-J 2064 type-E standards available in Yılkar air conditioning system, the minimum bending radius of these hoses and the unions used with these hoses are given in the table below.

  • Page 25: Clamp And Plastic Adapters

    1-First of all, cut the hoses straight. (one) 2-Lubricate the inner part of the hose where the union will pass. 3-Put the unions on the hoses properly. (2)(3) 4-Tighten the clamps with the help of pliers. (4)(5) HOSE YILKAR CODE: 212.01.P0000.05...
  • Page 26 Assemble 13/32 , 5/8 and 5/16 hoses to protect them from internal and external factors. Keep away from the moving elements and hot parts of the vehicle, make the assembly by isolating it from all sharp edges and corners where the line will pass.

  • Page 27: Electrical Connections

    4.5 Electrical Connections 4.5.1 Control Un t Mount ng Surface to be mounted YLK 12/24 Control unit The unit location should be ergonomically chosen as a flat surface in an area accessible to the driver. Mounting surface dimensions should be 90x45 mm. Assemble the control panel sockets to the unit as shown in the figure.
  • Page 28 Place the 80A fuse in the area of the bolts in the fuse box. Pass the M6 wire end of the 16 mm B+ cable in the mounting kit to one side of the fuse. Place the other M8 cable end on the (+) terminal of the vehicle's battery. Pass the M6 wire end of the 16 mm B+ wire to one side of the fuse.

  • Page 29: Wiring And Circuit Diagram

    4.5.2 W r ng and C rcu t D agram Outdoor Temperature Sensor Internal Temperature Sensor COMPRESSOR GENERATOR TERMINAL BOX 80A (-) Frame GND (-) Frame GND FOUR-WAY SWITCH BLOWER BLOWER ENGINE ENGINE LOW PRESSURE SWITCH BLOWER BLOWER ENGINE ENGINE CONDENSER ENGINE CONDENSER ENGINE (-) Frame GND...
  • Page 30 Description Cable Diameter and Colors 1. Fan Blower 1. Speed Orange 1.50 mm² 2. Fan Blower 2. Speed Grey 1.50 mm² 3. Fan Blower 3. Speed White 1.50 mm² 4. Condanser Engine Blue 1.50 mm² 5. Fan Controlled Motor Red 1.50 mm² 6.

  • Page 31: Control Unit Owerview

    4.5.3 Control Un t Owerv ew The digital controller helps to activate and deactivate the air conditioner by automatically adjusted set values with the help of temperature probes in the unit. 32° 18° 21° Increase set temperature Heating on / off (Optional) Decrease set temperature Flap open / close (Optional) Changing the fan speed...

  • Page 32: Control Unit Operation

    4.5.4 Control Un t Operat ng 4.5.4.1 Cool ng To start the cooling mode, press the cooling button. When the snowflake sign appears on 32° 18° the screen, your air conditioner operates 21° in cooling mode. 4.5.4.2 Heat ng (Opt onal) To start the heating mode, press the 18°...

  • Page 33: Fiber Cover Mounting

    4.6 F ber Cover Assembly 1960 1280 After all installations are completed, install the fiber cover before commissioning the air conditioner. Before installing the fiber cover of the air conditioner, make sure that the rubbers of the cover are fully inserted, then place it parallel to the vehicle roof so that it fits over the condenser.
  • Page 34 MONOBLOCK UNIT FINAL VIEW...

  • Page 35: Commissioning The Air Conditioner

    5. Commissioning the Air Conditioner Leakage Control of the System with Nitrogen; After giving Nitrogen gas to the system, leakage control is done with soapy water. The points to look at at this stage are the record connections. It should be observed whether there are air bubbles at the connection points.

  • Page 36: Spare Parts

    6. Spare Parts 6.1 Condenser Spare Parts CONDENSER MOTOR GROUP - 1301 - HP WING X2 PIECES 502.01.01301.02 CONDENSER BATTERY - ALM PIPE PARALLEL - 750X552X25,4 X1 PIECE 104.02.11016.02 COMPACT WAREHOUSE - Ø89 - MASTER - ALM X1 PIECE 104.09.CD002.89 PIPE - 1301 5/8X18 U OUTLET TANK INLET QUICK X1 PIECE 101.12.01301.04 SENSOR - COMPLETE - 2/15/25 BAR 4 WAy X1 PIECE...

  • Page 37: Evaporator Spare Parts

    PIPE - 1307 FILTER - VALVE - ADDITIONAL CONNECTION X1 PIECE 101.12.01307.10 PIPE - 1307 EVAPARATOR OUTPUT X1 PIECE 101.12.01307.09 SENSOR - EXTERNAL - 0.5-1.5 BAR LOW PRESSURE X1 PIECE 503.04.MDAB1.01 CABLE GROUP - EVAPARATOR MOTOR - YK 155 MB 113.12.YK155.01...

  • Page 38: Other Spare Parts

    6.3 Other Spare Parts FIBER - COVER - YK 155 MB x1 PIECE WICK - LUGGAGE RUBBER (5 m) 321.02.YK155.02 103.02.FT001.01 32° 18° 21° DIGITAL AIR CONDITIONER CONTROL PANEL x1 TERMINAL BOX x1 PIECE PIECE 503.92.KFSET.01 105.01.KU010.01 COMPRESSOR - SANDEN SD5S14...
  • Page 39 Original spare parts should always be used during repairs. Parts not approved by YILKAR may adversely affect the safety and proper operation of the unit. In such cases, the unit is out of WARRANTY. For a fast and accurate shipment of spare parts, we kindly ask you to provide the following information: 1.

  • Page 40: Usage And Maintenance Recommendations

    7. Usage and Maintenance Recommendations Perform routine maintenance of the system to improve the operation of the air conditioner. Before opening the cover of the air conditioner for maintenance and cleaning operations, disconnect the vehicle's battery. Protect electrical components while cleaning the system. At the beginning of each season, inspect all components of the system, including electrical components.
  • Page 42 Vehicle Heating Cooling and Ventilation Systems Phone : +90 224 215 53 28 (pbx) : +90 224 215 99 24 Address : Küçükbalıklı Mah. 580.Sok No:6 Osmangazi / BURSA / TURKEY www.yilkarklima.com...

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