YILKAR YK 140 MB Additional Installation Instruction
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YILKAR YK 140 MB Additional Installation Instruction

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Installation Instruction
YK 140 MB Additional
SSH.MT.01.04 - EN
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 140 MB Additional SSH.MT.01.04 - EN The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023...
  • Page 2 09.01.2023 H.Kübra Şahin First Publication REVISION NO PUBLISH DATE REVISING PERSON REASON FOR REVISION SSH.MT.01.04 - EN The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023...

  • Page 3: Table Of Contents

    4.Installation of Yılkar YK 140 MB Additional ............8 4.1 General Assembly Diagram ..............8 4.2 YK 140 MB Additional U Connection Profiles Mounting ......9 4.3 YK 140 MB Additional Unit Mounting ............11 4.3.1 Additional Unit Dimensions ............11 4.3.2 Additional Unit Roof Mounting ............
  • Page 4 5. Commissioning the Air Conditioner ..............6. Spare Parts ......................6.1. Evaporator Spare Parts ................6.2. Other Spare Parts ..................7. Usage and Maintenance Recommendations ............SSH.MT.01.04 - EN The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023...

  • Page 5: Ntroduction

    1. Introduction This instruction is part of the YK 140 MB Additional 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 140 MB Additional 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 140 MB Additional? YK 140 MB is an innovative designed roof top air conditioner developed for air conditioning minibuses with up to 17 additional seats. The easy-to-install unit includes an evaporator. These units need to be mounted on the roof of the vehicle and connected to the compressor via hoses with R134a refrigerant circulation.

  • Page 9: Yk 140 Mb Additional Technical Data

    2.3 YK 140 MB Additional Technical Data Table.1 Technical Data Roof Type Air Conditioning Unit YK 140 MB Additional * 6-14 kW Cooling Power (20472 - 47770 BTU/h) (5159 - 12037 kcal/h) Oil Type PAG 100 oil Oil Amount 250 ccm Refrigerant / Amount * R 134 a / 1000-1750 ±...

  • Page 10: Overview

    3.1 YK 140 MB Additional Overview 3.1.1. YILKAR Monoblock Un t EVAPARATOR UNIT - YK 140 MB 1 PCS 311.02.YK140.01 AIR SUCTION GRILL COMPLETE - GREY - YILKAR - 45X34 1 PCS 501.24.HEIPL.13 HOSE - STEEL WIRE - SPIRAL 12 MM 10 MT 108.02.HC00M.12...

  • Page 11: General Description

    3.2 Genel Tanımlama Fiber Cover The cover made of fiber material is mounted on the condenser unit on the vehicle roof and acts as a condenser protection. Evaporator Evaporator is an air conditioning system element that evaporates the R134a refrigerant coming from the condenser with the help of a valve and thus cools the ambient air.

  • Page 12: Installation Of Yılkar Yk 140 Mb Additional

    4. Yılkar YK 140 MB Additional Installation 4.1 General Assembly Diagram MASTER SLAVE CONDENSER COMPRESSOR VALVE YK 140 MB ADDITIONAL EVAPORATOR : Low Pressure L ne : H gh Pressure L ne Master : Ma n Product Slave : Add t onal Product...

  • Page 13: Yk 140 Mb Additional U Connection Profiles Mounting

    4.2 YK 140 MB Additional U Connection Profiles Mounting Connection plates are the parts that need to be assembled first, used to fix the evaporator to the vehicle roof and to each other. Just before this operation, remove the fiber cover and the evaporator plastic covers.
  • Page 14 Assembly Step 4: The position of the U connection profiles to be used for the evaporator should be marked on the roof in the vehicle as shown below and mounted to the roof with a drill-tipped trapezoidal M5x25 screw. 8 connection screws are used for this connection. VEHICLE ROOF 1117 FOR EVAPORATOR...

  • Page 15: Yk 140 Mb Additional Unit Mounting

    4.3 YK 140 MB Additional Unit Installation 4.3.1 Add t onal Un t D mens ons 1280 4.3.2 Add t onal Un t Roof Mount ng To fix the air conditioner, it is necessary to drill 3 holes in the roof of the vehicle for the unit.
  • Page 16 Assembly Step 5: Determine the location of the unit to be mounted on the vehicle with the central line on the vehicle in accordance with the mounting criteria. Assembly Step 6: For YK 140 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.
  • Page 17 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. INSULATION 1150 MONOBLOCK UNIT BOTTOM VIEW Assembly Step 8: Place the monoblock unit in such a way that it coincides with the cuts on the vehicle roof.
  • Page 18 Assembly Step 9: After applying silicone to the wedges, apply SIMSON ISR 70-03 white sealant around the area where the evaporator unit will be placed. Before applying, carefully read the silicone application section (p. 14).
  • Page 19 MONOBLOCK UNIT SILICONE APPLICATION 1- CLEANING Firstly, clean the surface to be siliconed with a dry, colorless and lint-free cloth. 5 minutes evaporation time is required. 2- PRIMER After cleaning, apply the primer. Do not apply the primer in a very thick layer as this may result in a weak boundary layer.
  • Page 20 MONOBLOCK UNIT TOP VIEW...

  • Page 21: Hoses And Fitting

    4.4 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. 5/16 HOSE AND FITTING CONNECTION Ø12 WATER HOSE...

  • Page 22: 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 23: Clamp And Plastic Adapters

    1-First of all, cut the hoses straight. (1) 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 24 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 25: 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 26 To protect the air conditioner, an additional terminal box set is used. The fuse box should be installed in an easily accessible area. 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.

  • Page 27: 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 Chassis ICE TERMOSTAT CONDANSER ENGINE CONDENSER ENGINE (-) Frame GND...
  • Page 28 Description 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. Fan Control Switch Orange 0.75 mm²...

  • Page 29: 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 30: 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 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.

  • Page 32: Fiber Cover Mounting

    4.6 F ber Cover Mount ng 1280 After all installations are completed, install the evaporator plastic covers and 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 33 MONOBLOCK UNIT FINAL VIEW...

  • 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

    6. Spare Parts 6.2 Evaporator Spare Parts EVAPORATOR BATTERY - ALM PIPE+BLOCK VALVE -2008 104.01.12005.14 X2 PCS 331.04.RLK03.01 (12V) RELAY BOARD ASSEMBLY - YLK 628 X1 PCS 331.04.RLK03.02 (24V) 105.10.BL12N.B1 (12V) FAN - BLOWER - 12V BASKURT 700 X2 PCS 105.10.BL24N.B1 (24V) VALVE - BLOCK - XINJING - 2220-01 X2 PCS 104.04.2XJ00.01...

  • Page 36: Other Spare Parts

    6.3 Other Spare Parts FIBER - COVER - YK 140 MB x1 PCS WICK - LUGGAGE RUBBER (5 m) 321.02.YK140.02 103.02.FT001.01 32° 18° 21° DIGITAL AIR CONDITIONER CONTROL PANEL TERMINAL BOX x1 PCS x1 PCS 503.92.KFSET.01 105.01.KU010.01...
  • Page 37 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 38: 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 40 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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