YILKAR YK 135 MB User manual

YK 135 MB
YILKAR
SSH.MT.01.09 - EN
The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023
EN
Installation Instruction

SSH.MT.01.09 - EN
The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023
00
03.01.2023
H.Kübra Şahin
First publication
REVISION NO
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SSH.MT.01.09 - EN
The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023
Contents
1 Warranty and Liability ..............................................................................1.
1.2 Security and Legal Regulations ...............................................................
3.Overview..............................................................................................................
4.Installation of Yılkar YK 140 MB...........................................................................
2. Definition and Technical Information ..................................................................
4.1 General Assembly Diagram ......................................................................
4.4 Hoses and Fitting .....................................................................................
4.4.1 Air Conditioner Hoses and Fitting Connections..............................
3.2 General Description...................................................................................
3.1 YK 140 MB Overview ..............................................................................
4.3 Monoblock Unit Mounting ........................................................................
4.3.1 YK 140 MB Unit Dimensions .........................................................
4.3.2 Unit Positioning and Roof Mounting ...........................................
1.2.1 ECE R-10 ....................................................................................
2.1 What is the YK 135 MB?.....................................................................
2.2 How does it work?..............................................................................
2.3 YK 135 MB Technical Data ..............................................................
4.4.1.1. Air Conditioner Hoses .......................................................
4.5 Electrical Connections .............................................................................
4.5.2 Wiring and Circuit Diagram.............. .............................................
4.5.1 Control Unit Mounting ..................................................................
4.5.3 Control Unit Owerview ...................................................................
4.2 YK 140 MB U Connection Profiles Mounting ............................................
3.1.1 YILKAR Monoblock Unit .................................................................
4.4.1.2. Fitting Sets ........................................................................
4.4.1.3. Clamp and Plastic Adapters ..............................................
4.4.1.4. Hose and Fitting Mounting ..............................................
4.5.4 Control Unit Operation ...................................................................
4.5.4.2 Heating (Optional) ...............................................................
4.5.4.3 Ventilating ..........................................................................
4.5.4.1 Cooling ...............................................................................
4.6 Fiber Cover Mounting ...............................................................................
1. Introduction ........................................................................................................

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SSH.MT.01.09 - EN
The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023
5. Commissioning the Air Conditioner ....................................................................
6. Spare Parts .........................................................................................................
7. Usage and Maintenance Recommendations .....................................................
6.1. Condenser Spare Parts ..........................................................................
6.2. Evaporator Spare Parts ...........................................................................
6.3. Other Spare Parts ....................................................................................

TR
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1. Introduction
This instruction is part of the YK 135 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.
It is recommended to be stored in a safe and clean place.
For questions, please contact the service and/or customer service.
You can scan the QR code for Yılkar Klima communication.
EN

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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.
All parts on the product are under warranty for 2 (two) years from the date of delivery in
case of fabrication defects.
If the relevant warranty form indicating that the product was installed at the approved
service points is not found in the business records, the date when the product was
decommissioned is taken as a reference. As of the date of exit from the business, the
warranty is processed for 2 years (two years).
Consumables (belt, bearing, refrigerant, workmanship, filter, dryer and compressor) are
covered by warranty for 1 year or 50,000 km (whichever comes first) from the date of
installation of the product.
In case the product fails during the warranty period, the time spent in repair is added to
the warranty period. This period starts with the delivery of the product to the authorized
service. The repair period of the product is maximum 30 days.
The warranty does not apply in the following cases:
Defects arising from the use or assembly of the product contrary to the points in the user
manuals
Faulty electrical wiring
Damages and malfunctions caused by using a voltage different from the voltage written
on the label of the product
If the product maintenance and repairs are not carried out on time, regularly, by the
services with the necessary technical knowledge and competence and in accordance
with the periodic maintenance and repair procedures (Every 50,000 km and annual
maintenance is obligatory).
The ownership of the parts changed within the warranty belongs to YILKAR.
The warranty period of products replaced by spare parts is 1 (one) year from the date of
installation.
1.1 Warranty and Liability
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Have repair and maintenance operations performed only by qualified personnel
who have received the necessary training and authorization. You can find
information about YILKAR authorized service centers on YILKAR's official website,
www.yilkarklima.com.
Do not reach into the unit and do not hold any foreign objects to the condenser and
evaporator fan when the device is in operation.
Please do not touch the condenser, evaporator or its connections with your hands.
The same is true for the resistor on the fan if it will run on the unit and it has not
cooled down completely.
Replace faulty parts immediately and have any detected faults corrected.
It is mandatory to use the necessary safety equipment in maintenance and repair
operations.
Carry out maintenance work only when the engines are turned off.
Before turning on the air conditioning unit, disconnect the battery.
Please pay attention to the following rules for your own safety:
1.2 Security and Legal Regulations
Read this service manual carefully before operating your YK 135 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.
ECE R10 – Electromagnetic compatibility regulation is the type approval test for
European automotive electronics. It has been successfully passed various tests including
RF immunity and emissions, transient immunity and emissions.
Electrically it has met the requirements for waste, explosion, fluctuating harmonics and
vibration.
As a result of the tests, it was certified with the document number E13 R10 - 05 13503.
You can reach Yılkar Klima ECE-R 10 test certificate via the QR code below.
1.2.1 ECE-R 10
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2. Definition and Technical Information
YK 135 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.
With its aerodynamic design, this unit only increases the height of the vehicle by 22 cm.
Thus, thanks to its design, resistance in air and fuel consumption is minimized.
It can operate in outdoor conditions at 45°. The air conditioner, which has a cooling
capacity of 8-13 kW, can have a heating function with the heat exchanger device. Your
air conditioner makes the waste heat generated in your vehicle's engine usable and can
provide heating power to your air conditioner with its current design. In this way, the
cooling of your engine is more effective, while your vehicle warms up.
YK 140 MB is universal, compact and economical with all its features.
2.1 What is YK 135 MB?
2.2 How does it work?
Vehicle roof air conditioners are heat machines that provide passenger thermal comfort
by taking the heat inside the vehicle.
Vehicle roof air conditioners work with a vapor compression refrigeration cycle in
thermodynamics. There are 4 main parts in this cycle. These are the compressor,
condenser, evaporator and expander valve.
The refrigerant put into the heat machine is first pressurized in the compressor, and the
fluid pressure is increased from approximately 1 bar to 16 bar. Afterwards, the
temperature of the supercompressed and superheated gas in the condenser is taken and
the fluid is liquefied under extreme pressure. The high pressure liquefied fluid coming to
the expansion valve from here passes through the valve to the low pressure region and
evaporates. It needs heat during evaporation. While the ambient air passed over the
evaporator heats the fluid in the evaporator and causes it to evaporate, it cools the
environment and provides thermal comfort to the passenger cabin.
EN

Roof Type Air Conditioning Unit
YK 135 MB
Compressor
SD7-TM16-TM21
Cooling Power
8 - 13.5 kW
(27297 - 46064 BTU/h)
(6878 - 11608 kcal/sa)
Oil Type
PAG 100 oil
Oil Amount
250 ccm
Refrigerant / Amount
R 134 a / 1500 ± 150 gr
Evaporator Fan Flow Rate
2000 m³/h (for 2 Blower Motors)
Condenser Fan Flow Rate
3400 m³/h (for 2 Axial Fans)
Pressure Switch
Low pressure / 2 bar
Fan Control / 15 bar
High pressure / 25 bar
Dimensions
(Length x Width x Height)
1760 x 1280 x 220 mm
Weight (Without Mounting Kit)
48,5 kg
Maximum Total Electricity Intake
47 A @12 VDC
23 A @24 VDC
2.3 YK 135 MB Technical Data
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Table.1 Technical Data

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MONOBLOCK UNIT - YK 135 MB
1 Piece
310.01.YK135.01
1
MONOBLOCK GROUP - YK 135 MB R1
1 Piece
500.22.YK135.02
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AIR SUCTION GRILL COMPLETE - GRAY - YILKAR - 45X22
1 Piece
501.24.HEIPL.08
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HOSE - STEEL WIRE - SPIRAL 12 MM
12,5 mt
108.02.HC00M.12
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AIR CONDITIONING - WEDGE CONNECTION COMPLETE - 20 MM
1 set
504.01.YKMON.01
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U - DOUBLE - RAIL-EAR 70 CM COMPLETE
3 sets
502.51.UC005.01
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WICK - LUGGAGE RUBBER
1 ADT
103.02.FT001.01
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AIR CONDITIONING - HOSE CONNECTION GROMMET
1 Piece
504.01.YKMON.33
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3. Overview
3.1 YK 135 MB Overview
3.1.1. YILKAR Monoblock Unt
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3.2 General Description
Fiber Cover
Condenser
The cover made of fiber material is mounted on the
condenser unit on the vehicle roof and acts as a
condenser protection.
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.
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.
It is an air conditioning system element that
provides the phase change by reducing the
refrigerant pressure.
Valve
Compact filter is a filter system that keeps the
impurities and moisture in the system positioned at
the condenser outlet.
Compact Filter
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Compressor
The relay switches on and off the current path with
the help of current and voltage values in the air
conditioning system. In this way, it ensures the
regular operation of the air conditioner. There are
12V and 24V options for the air conditioning system.
Relay Board
Air Conditioner Hoses
It is the pump of the system that compresses the
R134a air conditioner gas in the compressor air
conditioning system and increases its pressure.
There are 5/8'' 5/16'' and 13/32'' hoses in
compliance with SAE-J 2064 type-E standards in
the air conditioning system. Thanks to these hoses,
R134a refrigerant circulates between the air
conditioner elements.
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4.1 General Assembly Diagram
4. Yılkar YK 135 MB Installation
CONDENSER
VALVE
COMPRESSOR
EVAPORATOR
Hgh Pressure Lne
Low 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
the air conditioner system.
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4.2 YK 135 MB U Connection Profiles Mounting
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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 and evaporator plastic
covers 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.
Assembly Step 2:
Assemble the U profiles by interlocking the
rail-ear parts.
Assembly Step 3:
Spray the SIMSON ISR 70-03 white sealant
included in the mounting kit on the
evaporator and condenser U-profiles facing
the vehicle body..
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FOR EVAPORATOR
CONNECTION
U DOUBLE PROFILE
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815
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 M5,5x25 screw. 24 connection screws are used for this
connection.
VEHICLE ROOF
DRIVE
DIRECTION
FOR CONDENSER
CONNECTION U
DOUBLE PROFILE
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To fix the air conditioner, 12 holes must be drilled in the roof of the vehicle.
(4 for condenser connection wedges, 4 for evaporator connections, 3 for evaporator part
opening and 1 for grommet. )
4.3.2 Unt Postonng and Roof Mountng
1760
1280
220
4.3.1 YK 135 MB Unt Dmensons
4.3 Monoblock Unit Mounting
Before making any cuts on the vehicle, remove the vehicle's battery; Make
sure that there is no electrical cable in the part where you will drill the ceiling
holes.
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Ø13*4
..
.
..
.
145 145
180
290 290
20
500
405
92
390
815
815
390
137
.
815
90
13
730
140
.
Ø68
Assembly Step 5:
Determine the location of the condenser to be mounted on the vehicle with the central line
on the vehicle in accordance with the mounting criteria.
Assembly Step 6:
For YK 135 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.
ROOF TOP VIEW
DRIVE
DIRECTION
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145
565
660
50
50
465
INSULATION
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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.
MONOBLOCK UNIT
BOTTOM VIEW
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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.
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 10:
Place the monoblock unit on the vehicle roof so that it coincides with the mounting
wedges and the cut places. In order to mount the condenser on the vehicle roof, fasten it
to the wedges with M10 nut in accordance with it. Mount the evaporator to the vehicle
roof with M10 bolts.
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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.
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M10X50 Bolt
M10 Washer
M10 Nut
Bolt Connection
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