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Summary of Contents for YILKAR YK 400
- Page 1 YILKAR Installation Instruction YK 400 SSH.MT.01.10 - EN The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023...
- Page 2 15.03.2023 H.Kübra Şahin First publication REVISION NO PUBLISH DATE REVISING PERSON REASON FOR REVISION SSH.MT.01.10 - EN The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023...
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Page 3: Table Of Contents
1.2 Security and Legal Regulations ................1.2.1 ECE R-10 ..................... 2 Definition and Technical Information..................2.1 What is the YK 400? ................... 2.2 How does it work? ....................2.3 YK 400 Technical Data ..................3.Overview ..........................3.1 YK 400 Overwiew ...................... -
Page 5: Introduction
1. Introduction This instruction is part of the YK 400 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 400 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 400 ? YK 400 is an innovative designed roof top air conditioner developed for air conditioning 12 mt buses. The unit, which is easy to install, includes a condenser and two evaporators, right and left. -
Page 9: Yk 400 Technical Data
2.3 YK 400 Technical Data Table.1 YK 400 Technical Data Roof Type Air Conditioning Unit YK 400 Compressor BOCK FK40X/560K-655K 35 - 40 kW Cooling Power (34121 - 52888 BTU/h) (8598 - 13327 kcal/h) Oil Type PAG 100 oil Oil Amount... -
Page 10: Overview
3.1.1. YILKAR Monoblock Un t MONOBLOCK UNIT - YK 400 1 PCS 310.02.YK400.01 MONOBLOCK GROUP - YK 400 1 PCS 500.23.YK400.01 AIR SUCTION GRILL COMPLETE - YK 400 2 PCS 501.24.HEIPL.01 HOSE - STEEL WIRE - SPIRAL 12 MM 25 MT 108.02.HC00M.12... -
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.
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Page 13: Installation Of Yılkar Yk 400
4. Installation of Yılkar YK 400 4.1 General Assembly Diagram CONDENSER VALVE COMPRESSOR EVAPORATOR 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 400 Unit Mounting
4.2 YK 400 Unit Mounting 4.2.1 YK 400 Un t D mens ons 2450 2080 / 1930 / 1780 Th s d mens ons are opt onal accord ng to veh cle roof. 4.2.2 Un t Pos t on ng and Roof Mount ng Before making any cuts on the vehicle, remove the vehicle's battery;... - Page 15 Assembly Step 2: For YK 400, mark the places where holes will be drilled in the roof in the dimensions given in the technical drawing, with reference to the unit dimensions. Drill the marked places with suitable tools and equipment.
- Page 16 Assembly Step 3: After cutting the roof of the vehicle in accordance with your air conditioner, cut the 10 mm armaflex insulation material in accordance with the dimensions shown in the figure and insulate the roof. ROOF TOP VIEW 1680 1500 DRIVE DIRECTION...
- Page 17 Assembly Step 4: Lift your YK 400 air conditioner, which you will install, from the holes shown in the figure, and carry it to the vehicle roof. Make sure that your air conditioner is fully connected to these ports while carrying out the transportation, otherwise unwanted accidents may...
- Page 18 Assembly Step 5: Before installing the air conditioner you placed on the roof of the vehicle, remove the right, left and middle covers.
- Page 19 Assembly Step 6: After placing the unit, mount your air conditioner through the 16 holes shown on the roof. For mounting, pass the bolt under the roof and tighten with washer and nut over the unit. Bolt Connect on M10 Nut M10 Washer M10X50 Bolt...
- Page 20 Assembly Step 7: Apply SIMSON ISR 70-03 white sealant around the area where the unit is placed. To insulate the area between the condenser and the evaporator of the unit, open the grids on the unit as shown in the figure and apply SIMSON ISR 70-03 white sealant to this area.
- Page 21 YK 400 UNIT TOP VIEW...
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Page 22: Hoses And Fitting
4.3 Hoses and Fitting The air conditioning system is sent by the factory with a pressure of 20 bar inside. While removing the existing plugs at the connection points, it should be checked whether there is Nitrogen gas in it. 7/8"... -
Page 23: Air Conditioner Hoses And Fitting Connections
4.3.1 A r Cond t oner Hose and F tt ng Connect ons 4.3.1.1. A r Cond t oner Hose The hose types in compliance with SAE-J 2064 TYPE-B Class 1 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 24: Hose And Fitting Mounting
4.3.1.3. Hoses and F tt ng Mount ng 1- First of all, cut the hoses straight. 2- Lubricate the inner part of the hose where the union will pass. 3- Tighten the hose coupling to the hose properly with the help of a wrench. 4- Then tighten the hose-pipe coupling assembly to the union. -
Page 25: Electrical Connections
4.4 Electrical Connections 4.4.1 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 26 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.
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Page 27: Wiring And Circuit Diagram
4.4.2 W r ng and C rcu t D agram... - Page 28 Description Cable Diameter and Colors 1. Fan Blower 1. Speed Brown 0.50 mm² 2. Fan Blower 2. Speed Green 0.50 mm² 3. Fan Blower 3. Speed White 0.50 mm² 4. Blower (+) Red 1.50 mm² Blue 1.50 mm² 5. Condenser Fan Motor Orange 1.50 mm²...
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Page 29: Control Unit Owerview
4.4.3 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 30: Control Unit Operation
4.4.4 Control Un t Operat ng 4.4.4.1 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. 4.4.4.2 Heat ng (Opt onal) To start the heating mode, press the 18°... - Page 31 Table.5 Technical Information Table Supply Voltage 12 V - 24 V Average Electrical Consumption 400 mA @12V @25C Operating Temperature - 10 C --- + 40 C Fault Codes Fault code 21° E 1 : Inside Temperature Sensor Open Circuit Cause of Occurrence: The cable may have been cut or the socket may have come off.
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Page 32: Fiber Cover Mounting
4.5 F ber Cover Assembly After all installations are completed, attach the right, left and middle covers before commissioning the air conditioner. After making sure that you have placed it properly, mount it to the unit at the places shown in the figure with M6x25 bolts with torque head washer. - Page 33 MONOBLOCK UNIT FINAL VIEW...
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Page 34: 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 35: Spare Parts List
SHEET - 1403 MIDDLE COVER 1930 mm x2 PCS 101.11.01403.37 SHEET - 1403 MIDDLE COVER 1780 mm x2 PCS 101.11.01403.36 EVAPARATOR GROUP - YK 400 - 24 V - LEFT x1 PCS 501.23.YK400.22 EVAPARATOR GROUP - YK 400 - 24 V - RIGHT x1 PCS 501.23.YK400.21 CONDENSER GROUP - YK 400 - 24 V x1 PCS 502.13.YK400.21... -
Page 36: Condenser Spare Parts
CONDENSER MOTOR GROUP - 1301 - HP IMPELLER - 24V x4 PCS 502.01.01301.22 CONDENSER BATTERY - ALM PIPE PARALLEL-1860X422X25.4 x1 PCS 104.02.11014.02 LIQUID TANK - YK 400 x1 PCS 104.08.ST400.01 DRAER - 305 (5/8) x1 PCS 104.07.10305.01 SENSOR - 13-16 BAR FAN CONTROL x1 PCS 503.04.MDFK1.01... -
Page 37: Evaporator Spare Parts
6.3 Evaporator Spare Parts FIBER - RAW - YK 400 - BOTTOM BOWL x2 PCS 504.32.YK400.01 EVAPORATOR BATTERY - ALM PIPE+EXP VALVE - 1403 -RIGHT x1 PCS 104.01.11008.01 EVAPORATOR BATTERY - ALM PIPE+EXP VALVE - 1403 -LEFT x1 PCS 104.01.11008.02 RELAY BOARD ASSEMBLY - YLK610 - 24 V x2 PCS 331.04.RLK01.02... -
Page 38: Other Spare Parts
6.4 Other Spare Parts 32° 18° 21° DIGITAL AIR CONDITIONER CONTROL PANEL TERMINAL BOX x1 PCS x1 PCS 503.92.KFSET.01 105.01.KU010.01 COMPRESSOR - GEA BOCK FK 40X/560K x1 PCS 504.03.GBOFK.40 x1 PCS COMPRESSOR - GEA-BOCK FK 40X/655K x1 PCS 504.03.GBOFK.65 x1 PCS... - 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.
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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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