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YILKAR YK 300, Installation Instruction, Page: 22 / 42

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YILKAR YK 300 Installation Instruction Download Page 22

Stage

Ø12 WATER HOSE

7/8" HOSE AND FITTING

CONNECTION

1 1/8" HOSE AND FITTING

CONNECTION

18

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.

For  the  water  discharge  hose  connection,  the  clamps
located behind the stage in the evaporator water discharge
section  should  be  tightened  as  shown  in  the  figure.  Water
drain  hoses  should  be  inclined  at  least  2°  so  as  not  to
obstruct the water flow.

EN

Summary of Contents for YK 300

Page 1: ...EN YK 300 YILKAR Installation Instruction SSH MT 01 11 EN The right to make changes is reserved Printed in Turkey Yılkar Airconditioned 2023 ...

Page 2: ... 21 03 2023 H Kübra Şahin First publication REVISION NO PUBLISH DATE REVISING PERSON REASON FOR REVISION SSH MT 01 11 EN The right to make changes is reserved Printed in Turkey Yılkar Airconditioned 2023 ...

Page 3: ... Technical Data 4 3 1 1 Air Conditioner Hoses 4 4 Electrical Connections 4 4 2 Wiring and Circuit Diagram 4 4 1 Control Unit Mounting 4 4 3 Control Unit Owerview 3 1 1 YILKAR Monoblock Unit 4 3 1 2 Fitting Sets 4 3 1 3 Hose and Fitting Mounting 4 4 4 Control Unit Operation 4 4 4 2 Heating Optional 4 4 4 3 Ventilating 4 4 4 1 Cooling 4 5 Fiber Cover Mounting Introduction 1 5 Commissioning the Air C...

Page 4: ......

Page 5: ... 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 1 You can scan the QR code for Yılkar Klima communication EN ...

Page 6: ...rst 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 cont...

Page 7: ...sary 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 300 model roof type air conditioner In case of prob...

Page 8: ...le your vehicle warms up YK 300 is universal compact and economical with all its features 2 1 What is YK 300 4 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 ar...

Page 9: ...low Rate 4800 m h for 4 Blower Motors Condenser Fan Flow Rate 6600 m h for 3 Axial Fans Pressure Switch Low pressure 0 5 1 5 bar Fan Control 13 16 bar High pressure 21 5 28 5 bar Dimensions Width x Length x Height 2080 1930 1780 1990 270 mm Width is optional according to vehicle roof Weight Without Mounting Kit 150 kg Maximum Total Electricity Intake 85 A 24 VDC 2 3 YK 300 Technical Data 5 Table 1...

Page 10: ...UP YK 300 24 V 1930 mm MONOBLOK GROUP YK 300 24 V 2080 mm 1 PCS 500 23 YK300 01 500 23 YK300 02 500 23 YK300 03 2 1505 PLASTIC AIR SUCTION COMPLETE SET BLACK 2 PCS 501 24 HEIPL 11 3 HOSE STEEL WIRE SPIRAL 12 MM 25 MT 108 02 HC00M 12 2 3 Overview 3 1 YK 300 Overview 6 3 1 1 YILKAR Monoblock Unit EN ...

Page 11: ...ser 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 s...

Page 12: ... conditioner 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 7 8 and 1 1 8 hoses in compliance with SAE J 2064 TYPE B CLASS 1 standards in the air conditioning system Thanks to these hoses R134a refrigerant circulates between the air conditioner elements EN ...

Page 13: ... Installation of Yılkar YK 300 9 High Pressure Line Low Pressure Line 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 EN ...

Page 14: ...Positioning and Roof Mounting 2080 1930 1780 This dimensions are optional according to vehicle roof 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 roof holes EN 1990 270 ...

Page 15: ...ark 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 ROOF TOP VIEW DRIVE DIRECTION 11 Dimensions unit is milimeter EN 525 1120 Ø100 950 100 130 521 g 2080 446 g 1930 371 g 1780 854 g 2080 779 g 1930 705 g 1780 440 1990 200 400 150 450 220 85 ...

Page 16: ...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 INSULATION 12 Dimensions unit is milimeter ROOF TOP VIEW EN 230 200 50 1050 1220 DRIVE DIRECTION ...

Page 17: ...tioner 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 occur EN ...

Page 18: ...D RIVE D IRECTIO N Assembly Step 5 Before installing the air conditioner you placed on the roof of the vehicle remove the right left and middle covers DRIVE DIRECTION 14 EN ...

Page 19: ...placing the unit mount your air conditioner through the 12 holes shown on the roof For mounting pass the bolt under the roof and tighten with washer and nut over the unit M10X50 Bolt M10 Washer Bolt Connection M10 Nut 15 EN ...

Page 20: ...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 16 Insulated area EN ...

Page 21: ...YK 300 UNIT TOP VIEW 17 DRIVE DIRECTION EN ...

Page 22: ...of 20 bar inside While removing the existing plugs at the connection points it should be checked whether there is Nitrogen gas in it For the water discharge hose connection the clamps located behind the stage in the evaporator water discharge section should be tightened as shown in the figure Water drain hoses should be inclined at least 2 so as not to obstruct the water flow EN ...

Page 23: ...nce 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 Fitting sets used in Yılkar air conditioning system are shown in the table below 4 3 1 2 Fitting Sets 4 3 1 1 Air Conditioner Hose Table 2 Air Conditioner Hose Table Tablo 3 Air Conditioner Fitting Set T...

Page 24: ...ssembly to the union 4 3 1 3 Hoses and Fitting Mounting 20 Assemble 1 1 8 and 7 8 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 Bend the hoses to the minimum bending radius After all connections are made fix the hoses to the vehicle ...

Page 25: ...by inserting these nails onto the surface 4 4 Electrical Connections 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 Check the locks after assembling 4 4 1 Control Unit Mounting EN ...

Page 26: ...terminal of the vehicle s battery Complete the assembly of the cabinet set by attaching the nuts with M5 washer Finally connect the D ACC signal received from the vehicle s alternator with cable 1 via single sockets CABLE NUMBER 1 BATTERY Pass the M6 wire end of the 16 mm B wire to one side of the fuse Place the other M8 cable end to the pole of the relay board of the air conditioner B B EN ...

Page 27: ...4 4 2 Wiring and Circuit Diagram 23 EN ...

Page 28: ...range 0 50 mm 11 D ACC 1 NU Cable 0 50mm 12 Power Control 2 NU Cable 0 50mm 13 A C 3 NU Cable 0 50mm 14 FAN 1 4 NU Cable 0 50mm 15 FAN 2 5 NU Cable 0 50mm 16 FAN 3 6 NU Cable 0 50mm 17 Compressor 7 NU Cable 0 50mm 18 Internal Temperature Sensor Input 8 NU Cable 0 50mm 19 Common Connection Point Sensor 9 NU Cable 0 50mm 20 Outdoor Temperature Sensor Input 10 NU Cable 0 50mm 21 D ACC Blue 0 75 mm 22...

Page 29: ...ith the help of temperature probes in the unit 3 6 2 1 5 4 7 Set temparature Heating on Flap Closed Outside temparature Cooling on Fan speed Inside temparature 7 6 5 2 3 4 1 Flap Open 18 32 SET 21 Increase set temperature Decrease set temperature Changing the fan speed Open Close Flap open close Optional Heating on off Optional Display screen EN ...

Page 30: ...appears on the screen your air conditioner operates in cooling mode Press the fan stage button to start the ventilation mode If there is no snowflake or heating sign on the screen as a status indicator your air conditioner will operate in ventilation mode To start the heating mode press the heating button When the heating sign appears on the screen your air conditioner operates in heating mode opt...

Page 31: ...ature Sensor Open Circuit Cause of Occurrence The cable may have been cut or the socket may have come off The sensor may be faulty or broken Device Response When an error occurs the system shuts down and the error code is displayed on the screen Troubleshooting Check sensor cable and sockets If there is no problem with cables and sockets replace the sensor E 2 Outside Temperature Sensor Open Circu...

Page 32: ...ions 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 EN ...

Page 33: ...MONOBLOCK UNIT FINAL VIEW DRIVE DIRECTION 29 EN ...

Page 34: ...p The system is vacuumed by the vacuum pump connected by the compressor This process ensures that the air and moisture remaining in the system are discharged from the system with the vacuum pump before the refrigerant gas is supplied This should be done for at least 30 minutes 3 Gas Charge to the System R134a gas is charged to the system from the refrigerant charge records See Technical Data Table...

Page 35: ...1780 mm x2 PCS 101 11 01403 38 101 11 01403 37 101 11 01403 36 3 EVAPARATOR GROUP YK 300 24 V LEFT x1 PCS 501 23 YK300 22 4 EVAPARATOR GROUP YK 300 24 V RIGHT x1 PCS 501 23 YK300 21 5 CONDENSER GROUP YK 300 24 V 1780 mm x1 PCS CONDENSER GROUP YK 300 24 V 1930 mm x1 PCS CONDENSER GROUP YK 300 24 V 2080 mm x1 PCS 502 13 YK300 21 502 13 YK300 22 502 13 YK300 23 4 3 5 6 Spare Parts 31 ...

Page 36: ...ON x1 PCS 101 12 01403 04 8 PIPE 1403 FILTER OUTLET VALVE INLET RIGHT x1 PCS 101 12 01403 01 9 PIPE 1403 FILTER OUTLET VALVE INLET LEFT x1 PCS 101 12 01403 02 10 PIPE 1403 EVAP OUTPUT ADAPTOR EN 2080 mm x2 PCS PIPE 1403 EVAP OUTPUT ADAPTOR EN 1930 mm x2 PCS 101 12 01403 08 2080 mm 101 12 01403 07 1930 mm 11 PIPE 1403 EVAP INLET ADAPTOR EN 2080 mm x2 PCS PIPE 1403 EVAP INLET ADAPTOR EN 1930 mm x2 P...

Page 37: ...XM 700 BRUSHLESS x6 PCS 105 10 BL24B S1 17 SHEET 1403 EVAP WATER DRAIN PIPE RIGHT x2 PCS 101 11 01403 26 18 SHEET 1403 EVAP WATER DRAIN PIPE LEFT x2 PCS 101 11 01403 27 19 SHEET 1403 EVAP HINGE x2 PCS 101 11 01403 24 20 BALANCING CapIllary x2 PCS 104 10 KD001 01 21 INION 5 8X18 x2 PCS 108 07 11001 01 22 PIPE 1403 VALVE INLET ADAPTOR SANHUA x2 PCS 101 12 01403 20 13 21 19 16 17 14 15 12 18 20 22 Th...

Page 38: ...NDITIONER CONTROL PANEL x1 PCS 105 01 KU010 01 TERMINAL BOX x1 PCS 503 92 KFSET 01 6 4 Other Spare Parts EN COMPRESSOR GEA BOCK FK 40X 470K x1 PCS 504 03 GBOFK 47 x1 PCS COMPRESSOR GEA BOCK FK 40X 560K x1 PCS 504 03 GBOFK 40 x1 PCS ...

Page 39: ... 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 Your full address 2 Photocopy of your vehicle s license 3 Desired shipping format 4 Full description of the unit an...

Page 40: ...of inactivity Check the condenser coil regularly and if necessary clean it using compressed air without damaging the aluminum fins When working close to heat exchangers be careful not to injure yourself with the pointed ends of the fins Inspect the operation of the condenser electric fans When the air conditioner is started one of its engines starts The second fan is activated when the temperature...

Page 41: ......

Page 42: ...Vehicle Heating Cooling and Ventilation Systems Phone 90 224 215 53 28 pbx Fax 90 224 215 99 24 Address Küçükbalıklı Mah 580 Sok No 6 Osmangazi BURSA TURKEY www yilkarklima com ...

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