YILKAR YK 140 MB Additional User manual

YK 140 MB Additional
YILKAR
Installation Instruction
SSH.MT.01.04 - EN
The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023
EN

00
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

Contents
1 Warranty and Liability ..............................................................................1. 2
1
1.2 Security and Legal Regulations ................................................................ 3
3. Overview ............................................................................................................. 6
4.Installation of Yılkar YK 140 MB Additional ........................................................ 8
2 Definition and Technical Information .................................................................. 4
4.1 General Assembly Diagram ..................................................................... 8
17
18
3.2 General Description ................................................................................... 7
3.1 YK 140 MB Additional Overview ................................................................. 6
4.3 YK 140 MB Additional Unit Mounting ....................................................... 11
4.3.1 Additional Unit Dimensions ............................................................ 11
4.3.2 Additional Unit Roof Mounting ....................................................... 11
1.2.1 ECE R-10 ....................................................................................... 3
2.1 What is the YK 140 MB Additional?....................................................
2.2 How does it work? .............................................................................
2.3 YK 140 MB Additional Technical Data ...............................................
18
21
23
21
25
4
4
5
4.2 YK 140 MB Additional U Connection Profiles Mounting ........................... 9
3.1.1 YILKAR Monoblock Unit ................................................................. 6
18
19
19
26
26
26
26
4.6 Fiber Cover Mounting ............................................................................... 28
ntroduction ........................................................................................................1.
4.4 Hoses and Fitting .......................................................................................
4.4.1 Air Conditioner Hoses and Fitting Connections..............................
4.4.1.1. Air Conditioner Hoses .......................................................
4.4.1.2. Fitting Sets ........................................................................
4.4.1.3. Clamp and Plastic Adapters ..............................................
4.4.1.4. Hose and Fitting Mounting ..............................................
4.5 Electrical Connections ..............................................................................
4.5.2 Wiring and Circuit Diagram ...........................................................
4.5.1 Control Unit Mounting ..................................................................
4.5.3 Control Unit Owerview ...................................................................
4.5.4 Control Unit Operation ...................................................................
4.5.4.2 Heating (Optional) ...............................................................
4.5.4.3 Ventilating ...........................................................................
4.5.4.1 Cooling ...............................................................................
SSH.MT.01.04 - EN
The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023

30
31
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34
32
5. Commissioning the Air Conditioner ......................................................................
6. Spare Parts ...........................................................................................................
7. Usage and Maintenance Recommendations ........................................................
6.1. Evaporator Spare Parts ............................................................................
6.2. Other Spare Parts .....................................................................................
SSH.MT.01.04 - EN
The right to make changes is reserved. Printed in Turkey. © Yılkar Airconditioned, 2023

1
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.
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

2
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
EN

3
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.
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:
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 13505.
You can reach Yılkar Klima ECE-R 10 test certificate via the QR code below.
1.2.1 ECE-R 10
EN

2. Definition and Technical Information
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.
With its aerodynamic design, this unit only increases the height of the vehicle by 26 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 6-14 kW, can have a heating function by participating in the heat exchanger
device. Your air conditioner can use the waste heat generated in your vehicle's engine
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 the features it has.
2.1 What is YK 140 MB Additional?
2.2 How does it work?
4
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 140 MB Additional
Cooling Power
* 6-14 kW
(20472 - 47770 BTU/h)
(5159 - 12037 kcal/h)
Oil Type
PAG 100 oil
Oil Amount
250 ccm
Refrigerant / Amount
* R 134 a / 1000-1750 ± 150 gr
Evaporator Fan Flow Rate
2000 m³/h (for 2 Blower Motors)
Dimensions
(Length x Width x Height)
1280 x 825x 260 mm
Weight (Without Mounting Kit)
25 kg
Maximum Total Electricity Intake
33 A @12 VDC
17 A @24 VDC
2.3 YK 140 MB Additional Technical Data
5
*Depends on the features of the additionally connected master air conditioning system.
Table.1 Technical Data
EN

1
3
5
1
EVAPARATOR UNIT - YK 140 MB
1 PCS
311.02.YK140.01
2
AIR SUCTION GRILL COMPLETE - GREY - YILKAR - 45X34
1 PCS
501.24.HEIPL.13
3
HOSE - STEEL WIRE - SPIRAL 12 MM
10 MT
108.02.HC00M.12
4
U - DOUBLE - RAIL-EAR 70 CM COMPLETE
1 SET
502.51.UC005.01
5
WICK - LUGGAGE RUBBER
1 PCS
103.02.FT001.01
4
2
3. Overview
3.1 YK 140 MB Additional Overview
6
3.1.1. YILKAR Monoblock Unt
EN

2
3
3.2 Genel Tanımlama
7
4
5
1
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.
It is an air conditioning system element that provides
the phase change by reducing the refrigerant
pressure.
Valve
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
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.
EN

COMPRESSOR
EVAPORATOR
CONDENSER
VALVE
YK 140 MB
ADDITIONAL
4.1 General Assembly Diagram
4. Yılkar YK 140 MB Additional Installation
In the assembly diagram, the flow direction of the R134a refrigerant and low-high
pressure zones are shown on the components connected to each other by hoses in the
air conditioner system.
8
SLAVEMASTER
: Hgh Pressure Lne
: Low Pressure Lne
Slave : Addtonal Product
Master : Man Product
: Pont of connecton
EN

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.
9
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.
EN

10
1117
FOR EVAPORATOR
CONNECTION
U DOUBLE PROFILE
VEHICLE ROOF
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.
DRIVE
DIRECTION
EN

4.3.1 Addtonal Unt Dmensons
11
4.3 YK 140 MB Additional Unit Installation
To fix the air conditioner, it is necessary to drill 3 holes in the roof of the vehicle for the
unit.
4.3.2 Addtonal Unt Roof Mountng
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 ing holes.
1280
825
260
EN

120 120
256
296 296
38
455
379
12
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. Drill the
marked places with suitable tools and equipment.
DRIVE
DIRECTION
EN

13
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.
1150
145
145 565
660
50
50
465
INSULATION
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. Mount the evaporator to the vehicle roof with M10 bolts.
DRIVE
DIRECTION
EN

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).
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EN

15
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. Thin layer Primer is recommended for quality bonding.
Primer needs to be applied with a brush, pom-pom brush or
lint-free cloth to create a defined finish.
15 - 20 minutes evaporation
time is required.
MONOBLOCK UNIT SILICONE APPLICATION
3- PRACTICE
After applying the primer, open the Simson ISR package for application, do not damage the
thread on the top of the cartridge when opening. Apply the silicone to the relevant places as a
triangular structure. The main reasons for applying it in the form of a triangular structure are to
create the best wetting on both material surfaces, to prevent the high pressure needed during
adhesion and to prevent the formation of the form surface in the adhesion area.
EN

MONOBLOCK UNIT
TOP VIEW
16
DRIVE
DIRECTION
EN