Item Qty.PartNo.____________________________________________________________________________AIRBOXAB Ring Flange with 4" Con-Accessory 1 CC-SS RF-01AB Tray Template- Accessory 1 CC-SS PT-01SS Hose adaptor 4" Inside Intake 1 CC-SS FAI-BP-01AB Inside Filter Intake-Accessory 1 CC-SS FAI-01AB Outside Air Intake Assy-Accessory 1 CC-SS OAI-01AB Air Intake Mounting Plate Heater-Accessory 1 CC-SS AIMP-01620WD 4.0"ID Black Duct, EPDM W/Wire 8 ft CC-Duct DH8-02 Black10-16x3/4" HXWA Self-driller ZNC w/Washer 12 CC-Screw Driller 10/16x3/4Nylon Hold Down Strap 1"x12' Lashing Strap 1 CC-Strap Nylon Lashing6" Metal Hose Clamp 6 CC-Hose Clamp 6"1/4 Comm 5/8 OD F/W SS 4 CC-Washer 1/4-20 5/8 OD SS1/4" 20 SS Nylon Nut 4 CC-Nut Nylon 1/4-20 SS1/4-20 1" SS Bolt Hex 4 CC-Bolt 1/4-20 1" SS HexInside Air Filter 1 CC-Filter AC1/8" Metal Screen 3" x 3" 2 CC-Screen 1/8 3 x 3OptionalWoodFlooringKit 10-32 3 1/2" SS Bolt 4 CC-Bolt 10-32 3-1/2 SS Phil10-32 Hex Nylon Insert Locknut SS 4 CC-Nut Nylon 10-32 SS10-32 SS Split Washer 4 CC-Washer Split 10-32 SS____________________________________________________________________________THERMOSTAT10-32 x 1/4 Pan Phil M/S SS 2 CC-Bolt 10-32 1/4 SS Phil10-16x3/4" HXWA Self-driller ZNC w/Washer 2 CC-Screw Driller 10/16x3/4____________________________________________________________________________OUTLET10-32 x 1/4 Pan Phil M/S SS 2 CC-Bolt 10-32 1/4 SS Phil10-16x3/4" HXWA Self-driller ZNC w/Washer 2 CC-Screw Driller 10/16x3/4____________________________________________________________________________HEATER+AIR10-16x3/4" HXWA Self-driller ZNC w/Washer 4 CC-Screw Driller 10/16x3/4____________________________________________________________________________INVERTERInverter Drill Template 1 CC-SS DT-01SS 1/4-20 1" Bolt Hex 3 CC-Bolt 1/4-20 1" SS HexInverter Floor Cable Pass-Through Plate 1 CC-SS INV-FPT-01Inverter Shore Power Ring 1 1 CC-SS SP-01Inverter Shore Power Ring 2 1 CC-SS SP-02Shore Power Cable, 8' Long 1 CC-Shore Power Cable1/4" 20 SS Nylon Nut 3 CC-Nut Nylon 1/4-20 SS1/4 Comm 5/8 OD F/W SS 3 CC-Washer 1/4-20 5/8 OD SSMachined Solenoid Cover 1 CC-Box Solenoid CoverGrommet Edging, 1/8" 27" CC-Grommet EdgingThermoplastic Expandable Grommet 2 CC-Grommet, Expand 1" DiaOptionalWoodFlooringKit 10-32 3 1/2" SS Bolt 3 CC-Bolt 10-32 3-1/2 SS Phil10-32 SS Nylon Nuts 3 CC-Nut Nylon 10-32 SS10-32 SS Split Washers 3 CC-Washer Split 10-32 SS____________________________________________________________________________CONTROLBOXStainless Steel Top Plate for Control Box 1 NAS-CC-SS CB-TPColor Diagram of Connection Locations 1 NAS-CC-Diagram CB10-32 x 1/4 Pan Phil M/S SS 4 NAS-CC-Bolt 10-32 1/4 SS Phil10-16x3/4" HXWA Self-driller ZNC w/Washer 4 NAS-CC-Screw Driller 10/16x3/4____________________________________________________________________________BATTERYTRAYBattery Tray - Small 1 CC-SS BT-01Battery Tray - Large 1 CC-SS BT-02Battery Hold Down Bar - Small 1 CC-SS BT-03Battery Hold Down Bar - Large 1 CC-SS BT-043/8-16 x 1-1/2 Carr Bolt SS 8 CC-Bolt 3/8 1-1/2 SS Carr3/8 x 1-1/2 Fender Washer SS 8 CC-Washer 3/8 1-1/2 SS Fend3/8" SS 16 Nylon Nut 8 CC-Nut Nylon 3/8-16 SS1/4-20 1" SS Bolt Hex 4 CC-Bolt 1/4-20 1" SS Hex1/4" 20 SS Nylon Nut 4 CC-Nut Nylon 1/4-20 SSBattery Ends 18ga SS 2 CC-SS BT-ECBattery Tray Insulation Kit 1 CC-Floor Mats BT-INS3/8-16 X 3-1/2 Carr Bolt GALV 8 CC-Bolt 3/8 3-1/2 Galv Carr3 x 3 Battery Harness Assembly 1 CC-BH 3 x 33X3BATTERYHARNESSASSEMBLYCABLESTruck Battery Positive to Solenoid w/Fuse 178" Solenoid to Inverter Positive to Battery Bank 1 Positive 48"Battery Bank 1 Positive Bus 15" Truck Ground to Battery Bank 1 Ground 178"Battery Bank 1 Negative Bus to Inverter Negative 43" Battery Bank 2 Positive Bus w/Link 104" Battery Bank 2 Negative Bus w/Link 104"

Comfort CabBattery Operated Truck Cab HVAC

Installation Options• Single Inverter Installation which will power

heat and air conditioning• Dual Inverter Installation with one Inverter

dedicated to powering heat and air conditioning and a secondary Inverter dedicated to providing power to a Power Outlet to power your AC appliances

• Dual Inverter installation with one Inverter dedicated to powering heat and air conditioning and utilizing your existing Inverter in place of the secondary Inverter dedicated to providing power to the Power Outlet to power your AC appliances

Tools for Installation• Power Drill • #10 Driver Bit• 3/8", 1/4", 1" Drill Bits • Tape Measure• Socket Wrench Set SAE • Wire Cutters• 8-9" Socket Set Extension • Flathead Screwdriver• Silicone • Phillips Screwdriver • Volt/DC Amp Meter • Marking Pen • Battery Terminal Spray • Channel Locks• De-burring Tool/File • Zip Ties (Included)• Jig Saw/Metal Blade or Circular Hole Saw• 1", 2", 2-1/2", 4-1/2" Bimetal Hole Saws

Extremely Important!It is extremely important you have technical ability and electrical knowledge to install the Comfort Cab system properly. If you do not have the technical ability or any experience with installing electrical cabling and components, it is highly recommended to have an experienced professional install your Comfort Cab system.

COMFORT CAB PARTS LIST

1

THERMOSTATOUTLET

INVERTER

FLOOR CABLEPASS-THROUGH

PLATE

HEATER+ AIR

AIR BOX

TRUCK BATTERY BANK

SHORE

INTAKE

BATTERYBANK 1

SOLENOID

CONTROLBOX

EXHAUST

3

1

2

2

5

433

3

5

BATTERYBANK 2

5

4

INSTALLATION PLACEMENT OVERVIEW

COMFORT CAB INSTALLATION

2

Before Getting Started...Pleasereadandreviewtheentireinstallationmanualbeforeproceeding.Theinstructionsareageneralguideasplacementoptionsandconfigurationwillvarybyvehicle.Before Cutting or Drilling:

• Lay out all of the large parts to determine optimal placement in truck especially taking into account the length of cables. Also, check exterior of truck for obstructions to cutting and drilling.

• Airbox placement needs 4-5" of clearance if it is necessary to have a 90º bend in the air duct hose.

• Any holes drilled in the exterior, exposed wood or composite flooring must be sealed with silicone (not included) to protect from outside elements.

• If the interior storage compartments are sealed then interior holes must be drilled to help circulate warm airflow to batteries for maximum efficiency and life.

Cable Care and Safety:

• When connecting cables to batteries ensure there is a good connection and protect with a commercial protectant spray (not included).

• Make sure zip ties are tight to reduce friction and keep all cabling away from sharp metal.

• Make sure any holes for electrical or battery cables have grommets installed to protect the integrity of the cables from vibrational wear.

7” 7” 88” 104” Total

Battery Bank 2 Negative Bus w/Link (BLK)

177” Total

Truck Battery Positive to Solenoid w/Fuse (RED)

11” 35” 48” Total

Solenoid to Inverter Positive to Battery Bank 1 Positive (RED)

7” 7” 15” Total

Battery Bank 1 Positive Bus (RED)

177” Total

Truck Ground to Battery Bank 1 Ground (BLK)

7” 7” 27” 43” Total

Battery Bank 1 Negative Bus to Inverter Negative (BLK)

7” 7” 88” 104” Total

Battery Bank 2 Positive Bus w/Link (RED)

Air BoxHeater + Air

Outside Intake Outside Intake4” Duct w/Screen

Shore Power

Shore PowerRing x 2

Thermostat

ThermostatMounting Plate

Control Box

Inverter Rack with Inverter and Solenoid

Outlet

OutletMounting Plate Battery Trays x 2

Floor Cable Pass-Through Plate

(Floor Plate)

A A

B B B

C C C

D D

E E E E

F F F F

G G G G

Inside Intake Inside Intake2”Duct

RelayDual Inverters

Only

PARTS OVERVIEW

COMFORT CAB INSTALLATION

3

CONTROL BOX WIRING1

CONTROL BOX PLACEMENT11. Mount the Control Box on vertical surface allowing access to spade terminals.

2. Do not block Control Box fan intake or exhaust grill or the Control Box will overheat.

3. Mount for easy access to Shore Reset and for AC Power Reset circuit breakers.

4. Allow at least 2" inch clearance for safe wire pass through after installing back plate.

5. If mounting the Control Box to bare sheet metal use the 3/4" Self-driller screws.

6. If mounting the Control Box to multiple layers of materials such as sheet metal, carpet, plywood, etc. use the 1" 1/4 diameter bolts and nylon nuts.

CONTROL BOX MOUNTING1

CONTROL BOX

4"

Connect the Ground Strap to any negative terminal of the Comfort Cab's Battery Bank (After batteries are installed, Page 11.)

Ground Strap

3/8"

1/4"

4

SHORE POWER WIRING2 THERMOSTAT WIRING2

1. Mount the Shore Power a few inches above the floor on a vertical surface of the rear cab wall to the outside.

2. Locate the Shore Power for convenient access from the outside.

3. Silicone around holes to mount Shore Power to cab exterior.

1. Mount the Thermostat 40" inches or more above the floor on a vertical surface.

2. Do not place the Thermostat in front of or near heat or cold vents, this will prevent the Thermostat from obtaining a true reading of the environment temperature.

SHORE POWER MOUNTING2 THERMOSTAT MOUNTING2

SHORE POWERSHORE POWER PLACEMENT2 THERMOSTAT PLACEMENT2

THERMOSTAT

B W G

B W G

B W G

r w_bs

or bl

B W G

B W G

B W G

B W G

B W G

r w_bs

or bl

B W G

B W G

Silicone

Control Box Control Box

3/4"

2"

Cab Exterior

5

RetainingNut

Shore

AIR BOX WIRING3

AIR BOX PLACEMENT31. Place Air Box Tray on floor and check for subfloor beams.

2. Allow space for air duct bends.

3. Drill exhaust port with 4-1/2" hole saw and condensation holes with 1"drill bit.

4. Silicone around the exhaust port and condensation holes before mounting tray to floor with 3/4" Self-driller screws.

5. Strap Air Box to Air Box Tray.

AIR BOX MOUNTING3

AIR BOX

AIR BOX AIRFLOW3

B W G

B W G

B W G

r w_bs

or bl

B W G

B W G

Silicone

Zip-tied

4-1/2"

1"

Control Box

6

InsideIntake

Heater + Air

OutsideIntake

Exhaust Blower

Air

INSIDE INTAKE MOUNTING3 HEATER + AIR WIRING3

1. Outside Intake: Place Outside Intake on the exterior rear wall of cab with the louvers facing down for rain protection.

A. Silicone around holes before mounting Outside Intake to cab exterior with 3/4" Self-driller screws.

2. Inside Air Intake: Place Inside Intake with louvers facing down for easy placement of the filter screen from the top edge. Do not block.

1. Place Heater + Air unit top side up or it will not work at all. 2. The hole for the power cord should be at the bottom center and the circuit breaker should be at the bottom left corner.

OUTSIDE INTAKE MOUNTING3 HEATER + AIR MOUNTING3

OUTSIDE & INSIDE INTAKEINTAKE PLACEMENT3 HEATER + AIR PLACEMENT3

HEATER + AIR

B W G

B W G

B W G

r w_bs

or bl

B W G

B W G

Silicone

Control Box

Cab Exterior4-1/2" 4-1/2"

Silicone

Filter

1"

7

4-1/2"

Heater

INVERTER WIRING4

INVERTER RACK WITH SINGLE INVERTER PLACEMENT41. Allow Inverter to have "breathing room" of at least 2-3 " all around.

2. Keep conductive metals and liquid away from Inverter.

3. Observe all polarity.

4. Insulate with electrical tape.

5. Use lock washers and/or anti-vibration nuts.

6. Silicone around holes before mounting Inverter Rack to floor with 3/4" Self-driller screws.

INVERTER RACK MOUNTING4

INVERTER RACK WITH SINGLE INVERTER

B W G

B W G

B W G

r w_bs

or bl

B W G

B W G

Control Box

8

Silicone

Inverter

Inv SW

INVERTER RACK WITH DUAL INVERTER PLACEMENT4

DUAL INVERTER WIRING41. Mount the Outlet in a convenient location for access to AC power for AC appliances.

OUTLET MOUNTING4

OUTLET PLACEMENT4

INVERTER RACK WITH DUAL INVERTER

B W G

r w_bs

or bl

B W G

B W G

B W G

B W G

Control Box

Female Spade ConnectorMale Spade Connector

3/4"

Outlet

Relay toControl Box

Inverter B Plug

Relay

9

1. Allow Inverters to have "breathing room" of at least 2-3 " all around.

2. Keep conductive metals and liquid away from Inverter.

3. Observe all polarity.

Inv SW

Inverter A

Relay

BA

BATTERY TRAY PLACEMENT51. Leave slack on cable between frame and cab to allow for cab suspension float.

2. Battery Trays are installed in the driver-side and passenger side compartments to even weight distribution for cab suspension float.

3. Silicone around holes before mounting Battery Trays to floor with 3/4" Self-driller screws.

4. Secure cables with supplied zip ties every foot.

5. Do not allow cables to rub on surfaces that will wear through the cable's insulation.

6. Apply power to system as the last connection after double checking the connections.

7. Use lock nuts or lock washers on all connections to ensure longevity of connection.

8. Insulate with electrical tape.

BATTERY TRAY MOUNTING5

BATTERY TRAYS

1. Mount the Floor Cable Pass-Through Plate in a convenient location to the Inverter and Battery Tray.

2. Silicone around holes before mounting Floor Plate to floor with 3/4" Self-driller screws.

FLOOR PLATE MOUNTING5

FLOOR PLATE PLACEMENT5

2-1/2"

10

Silicone

Silicone

SiliconeSilicone

Silicone

BATTERY TRAYSBATTERY WIRING5

B W G

B W G

B W G

r w_bs

or bl

B W G

B W G

AF F F

Battery Bank 2 Battery Bank 1

G GD

EE

CCCB

E

D

F

G

Control Box

Truck Battery Bank11

Silicone

CONNECT LAST

CONNECTSECOND TO LAST

RED BLK

BLK

RED

*RED SENSOR

Solenoid to Inverter Positiveto Battery Bank 1 Positive (B)

Inverter A

GroundStrap

Solenoid

IMPORTANT!*RED SENSOR lead must be on the same Solenoid post as the fused truck battery cable connection.

Battery Bank 1 Negativeto Inverter Negative (E)

ToControl Box

Truck Battery Positiveto Solenoid w/ Fuse (A)

Inv SW Solenoid

Inverter

A

YES, please contact me with more information.

Name: 

Address: 

City: 

State:     Zip: 

Phone: 

E-mail: 

Number of  trucks  which could use our APU system: 

Outlet for optional AC equipment.

NALLCS

NAS, LLC1345 Monroe Avenue NWGrand Rapids, MI  49505

616.454.2616616.451.2688

www.thecomfortcab.com

e-mail contact: jimreed@ameritech.net

Comfort CabBattery Operated Truck Cab HVAC

Warmer Warmth& Cooler Cool

Zero EmissionsSaves Fuel

Anti-Idle Compliant

• Single Unit - Heating and Cooling• Compact Modular Design - All in-cab• EZ Installation• EZ to Transfer• Minimal Modifications Required• Stainless Steel Construction• Automatic Recharge Long Life Battery Pack• Powers Your Optional AC Equipment• Integrated AC Shore Power Outlet• In-cab Controls• Low Battery Indicator• Over 8.5 Hours of Normal HVAC Operation• Quiet Operation

Beats No-IdleRegulations – NOW

616.454.2616www.thecomfortcab.com

NALLCS

Congratulations! You have installed the

Comfort CabBattery Operated Truck Cab HVAC

Questions/Troubleshooting Call 616-454-2616

1. Do not hang objects that will block the Thermostat, this will prevent the Thermostat from obtaining a true reading of the environment temperature.

2. Periodically check all cables for wear and check for loose connections.

3. Turn environment and inverters off while driving or not in use.

4. Clean the filter in the Inside Intake at regular intervals.

GENERAL OPSPERFORMANCE TIPS

© 2010 NAS LLC.