Comfort CabBattery Operated Truck Cab HVAC

Warmer Warmth& Cooler CoolZero Emissions

Saves FuelAnti-Idle Compliant

• SingleUnit-HeatingandCooling• CompactModularDesign-Allin-cab• EZInstallation• EZtoTransfer• MinimalModificationsRequired• StainlessSteelConstruction• AutomaticRechargeLongLifeBatteryPack• PowersYourOptionalACEquipment• IntegratedACShorePowerOutlet• In-cabControls• LowBatteryIndicator• Over8.5HoursofNormalHVACOperation• QuietOperation• Sixbatterysystemwiththreebatteriesper sideevenlydistributesweightforAirRidecabs• Systemsensesvoltageschangeswhenignition isengagedanddisengagedandwillneveruse maintruckbatteries• Maintainsamplestoragespaceforfire extingiushersandroadtrianglereflectors

Tips Before Getting Started...Please read and review entire installation instructions before proceeding. These instructions are a general guide as placement options and configuration will vary by vehicle.

Beforeanycuttingordrilling:Layoutallofthelargepartstodetermineoptimalplacementintruckespeciallytakingintoaccountthelengthofcables.Also,checkexterioroftruckforobstructionstocuttinganddrilling.

Airboxplacementneeds4-5"ofclearanceifitisnecessarytohavea90ºbendintheairducthose.

Anyexposedwoodorcompositeflooringmustbecompletelysealedwithsilicone(notincluded)toprotectfromoutsideelements.

Iftheinteriorstoragecompartmentsaresealedthenholesmustbedrilledtohelpcirculatewarmairflowtobatteriesformaximumefficiencyandlife.

Whenconnectingcablestobatteriesensurethereisagoodconnectionandprotectwithacommercialprotectantspray(notincluded).

Makesureziptiesaretighttoreducefrictionandkeepallcablingawayfromsharpmetal.

Makesureanyholesforelectricalorbatterycableshavegrommetsinstalledtoprotecttheintegrityofthecablesfromvibrationalwear.

Tools Needed for Install...PowerDrill #10DriverBit3/8",1/4",1"DrillBits TapeMeasureSocketWrenchSetSAEWireCutters8-9"SocketSetExtensionFlatheadScrewdriverSilicone PhillipsScrewdriver Volt/DCAmpMeter MarkingPen BatteryTerminalSpray ChannelLocksDe-burringTool/File ZipTies(Included)JigSaw/MetalBladeorCircularHoleSaw1",2",2-1/2",4-1/2"BimetalHoleSaws

COMFORT CAB INSTALLATION PARTS LIST Item Qty. Part No.____________________________________________________________________________Air Box 1 CC-AB TemplatewithTwo41/2"Holes 1CC-41-2ABMountingTray 1CC-MT-01DuctHose8’ 1CC-DH8-01AirIntakeMountPlate 1CC-AIMP-01NylonHold-DownStrap 1CC-NHDSHoseClamps4-1/2” 6CC-4-1/2"HoseClampSSHexHead1/4-201"Bolt 4CC-SS1/4-201"BoltSSHex1/4-20NylonNut 4CC-SS1/4-20NylonNutSS1/4"IDWasher 4CC-SS1/4"WasherSSVentforRearIntake 1CC-OAI-01FilterScreenforRearIntake5"x5" 1CC-ABF-02SSHoseadaptor4"HoleRearIntake 1CC-RF-01SSVentforInsideIntake 1CC-FAO-01SSHoseAdaptor4"InsideIntake 1CC-FAI-BP-01FilterforInsideIntake 1CC-AFB-01SSScreen1-1/2"x2" 2CC-1-1/2x2MetalScreenSSScreen4"x5" 1CC-4x5MetalScreen3/4"DrillerScrews(#10SelfTap) 12CC-3/4"DrillerOptionalWoodFlooringKit 3-1/2"SS10-32Bolt 4CC-3-1/210-32Bolt____________________________________________________________________________Thermostat 1 CC-TH ModularNetworkCord14’ 1CC-ModNetCordSS10x32x1/4"Bolt 2CC-10x32x1/4"Bolt3/4"DrillerScrews(#10SelfTap) 2CC-3/4"Driller____________________________________________________________________________Outlet 1 CC-OT3/4"DrillerScrews(#10SelfTap) 2CC-3/4"DrillerSS10x32x1/4"Bolt 2CC-10x32x1/4"Bolt____________________________________________________________________________Heater/Exhaust Module (CC-HTR) 1 CC-Heater/Exhaust Module (CC-HTR)10-32x1/4”SSScrews 4CC-10-32x1/4”SSScrews3/4"DrillerScrews(#10SelfTap) 2CC-3/4"DrillerHeat/CoolAirDeflector 1CC-HTR-AD____________________________________________________________________________Inverter 1 CC-INVInverterDrillTemplate 1CC-DT-01ShorePowerConnector 1CC-INVSP-01 ShorePowerRing1 1CC-SP-01ShorePowerRing2 1CC-SP-01SSHexHead1/4-201"Bolt 3CC-SS1/4-201"BoltSSHex1/4-20NylonNut 3CC-SS1/4-20NylonNutSS1/4"IDWasher 3CC-SS1/4"Washer3/4"DrillerScrews(#10SelfTap) 4CC-3/4"DrillerFloorPassThroughPlate 1CC-FPT-01GrommetMaterial 2CC-GE-01SolenoidCover 1CC-SC-01OptionalWoodFlooringKit 31/2"SS10-32Bolt 3CC-31/210-32Bolt____________________________________________________________________________Battery Tray (NAS-BT) 2 CC-BTBatteryTraysLarge 2CC-BT-LGBatteryTraysSmall 2CC-BT-SMSSHexHead1/4-201"Bolt 4CC-SS1/4-201"BoltSSHex1/4-20NylonNut 4CC-SS1/4-20NylonNutSS3/8”CarriageBolts1-1/2” 8CC-SS3/8”CarriageBolts1-1/2”SS3/8”FenderWashers 8CC-SS3/8”FenderWashersSS3/8”NylonNuts 8CC-SS3/8”NylonNutsBatteryPostClampNuts 12CC-3/16"ClampNutsSSBatteryHolddownBarset 1CC-BTHDRubberBatteryCovers 4CC-RBC-01RubberBatteryMats 2CC-RBM-01RubberBatterySpacers 4CC-RBS-01OptionalWoodFlooringKit SS3/8-1631/2"CarriageBolts 8CC-SS3/8-1631/2"CarriageBolts____________________________________________________________________________Battery Harness AssemblyRedPositiveCableW/3Connectors15" 1CC-PR-15-01BlackNegativeCableW/4Connectors43" 1CC-NB-43-01RedPositiveCableW/3Connectors48" 1CC-PR-48-01BlackNegativeCableW/4Connectors104" 1CC-NB-104-01RedPositiveCableW/4Connectors104" 1CC-PR-104-01BlackNegativeCableW/2Connectors178" 1CC-NB-177-01RedPositiveCableW/2Connectors&Fuse178" 1CC-PR-166-01____________________________________________________________________________Control Box 1 CC-CB-01 ControlBoxTemplate 1CC-CBT-01SS10-32Pan1/2"Bolt 4CC-SS10-32Pan1/2"Bolt3/4"DrillerScrews(#10SelfTap) 4CC-3/4"DrillerGrommetMaterial 1CC-GE-01____________________________________________________________________________MiscellaneousGromets 1CC-MG-01

4c

3c3b

1i1g, 1h

1e, 1f1d

1j

2d2c

Comfort Cab APU and Wiring Kit Installation InstructionsIMPORTANT: Please read and review entire installation instructions before proceeding. Placement options and configuration vary by vehicle.Preparation: Disassemble lower bed area by taking out mattress and metal cover plate (where applicable).Airbox Frame Alignment and Installation (Figure 1)a) AlignandplaceAirboxTrayTemplateonfloorareabeneathbed.

Placeframe’slongestsidefacingfrontofcabandcenterwithinarea.Ifinstallingflushwallmount,buttthefrontoftheAirboxTrayTemplateagainstbackofwall.Ifthereisinsulationonfloor,outlinetrayandcutawayinsulationtoexposebarefloor.

b) Positiontemplatewithtwo4-1/2"holesandmarkonfrontofwallsoairducthoseswilllineupwithintakeandexhaustports.

c) Drillthetwo4-1/2"ductholesinlowerwallwith4-1/2"holesaw.d) MarkductedexhaustportandcondensationholesfromAirbox

TrayTemplate.NOTE: Check beneath vehicle to ensure area below frame for drilling is clear of cabling or rig structure.

e) LiftAirboxTrayTemplateoffandsetaside.f) Drillexhaustportwith4-1/2"holesaw.Drillcondensationholeswith

1"bit.NOTE: Vacuum shavings to avoid embedding into carpet.g) Siliconeasealingbeadaroundallthreedrilledholes.h) Placelargemeshscreenoversiliconearoundexhaustportand

placefinemeshscreensoversiliconearoundcondensationholes.i) CarefullyreplaceAirboxTrayTemplateoverexhaustportand

condensationholesandaffixittofloorwith3/4"Drillerscrews.j) Threadyellowtie-downstrapsincludedinkit,thougheyeletsin

AirboxTrayTemplateandsecurewithratchetmechanism.Rear Intake Vent Alignment and Installation (Figure 2)a) DeterminedesiredplacementforRearIntakeVentinrearwall.

NOTE: The duct should enter under-bed area above topmost surface of decking, i.e., insulation. Also, when mounted, Rear Intake Vent should be close to Airbox intake port and must avoid any structural cross members or cables along rear wall.

b) DrillRearIntakeVentductholewith4-1/2"holesaw.c) SiliconearoundholeandinsertRearIntakeHoseHolder.Silicone

FilterScreenforRearIntaketotheRearIntakeHoseHolder.d) AffixRearIntakeVentwithlouversfacingdowntoexteriorofcab

with3/4"Drillerscrews.Shore Power Connection (Figure 3)a) Oninsidebackwalllocatelowerdriversidecornerofunder-bed

areaandfindapositiontodrillholeforShorePowerConnector.NOTE: It should be at least an inch above the upper floor area to avoid any cross members and/or cabin insulation.

b) DrillholeforShorePowerConnectorwith2"holesaw.NOTE: Vacuum shavings to avoid embedding into carpet.

c) SiliconeasealingbeadbetweenexteriorconnectorandrearwalltoavoidenvironmentalorwaterleakagetoinnercompartmentandsecureShorePowerConnectionwithSilicone.

d) Runpowercordtopassengerstoragecompartmentinterioraccess.

Front

1a, 1b

2b

3a

3d

1b

1a

2a

3d

(Flush Wall Mount)

(Regular Wall Mount)

6a

4f

4b

5

Thermostatic Controller

Power Outlet

4e

4c

5c

5b5a

5d 5e

5f 6b

Heater/Exhaust Module Mounting Assembly (Figure 4)Thiskitoffersthreemountchoicesdependingonvehicletype/layout.If...Under-bedareaiscantilevered,withkick-spacebeneathsofabed,Heater/ExhaustModulecanbeflushmountagainstinnerwallandducttoasecondarymountingplate.Or...Ifbedareadropsstraightdowntofloorfrommattress,thiskitoffersaflexiblemountingducttoallowbothintakeandexhausttorecirculatedirectlywithinthecompartment.Or...IfthereisnowallunderbeduseoptionalAirIntakeMountPlatetomounttheHeater/ExhaustModule.Note: If mounted with this method ensure filter is installed with side access (see Figure 4g). a) AttachproperductfittingtoAirbox(determinedbyconfiguration).b) Drill1"holetofeedmalespadeconnectorsandwiringthrough.

NOTE: Vacuum any shavings.c) AffixHeaterandExhaustVentwith3/4"Drillerscrews.

NOTE: Make sure flow sensor is centered within heater.d) RunAirboxandHeatercordstopassengerstoragecompartment

interioraccess.e) AttachductstoRearIntakeVent,HeaterandExhaustVentwith

hoseclamps.f) InsertfilteratExhaustVent.g) ConfigurationofoptionalAirIntakeMountingPlate.NOTE: For

safety attach grommet material to exposed edges.Thermostatic Controller & Power Outlet (Figure 5)PositionThermostaticControlleronpassengersidewall.(See Figure 5)NOTE: Temperature control is more accurate if Thermostat is mounted on an interior wall.a) Drill3/4"holetofeedmalespadeconnectorsandwiringthrough.

NOTE: Vacuum any shavings.b) FeedThermostatControllerwiringthroughhole,positionand

attachMountingPlatewith3/4"Drillerscrews.c) PositionandfastenThermostaticControllertoMountingPlate.PositionPowerOutletMountingPlateasaguideandmountafewinchesaboveflooralongrearwall.(See Figure 5)d) Drill3/4"holetofeedmalespadeconnectorsandwiringthrough.

NOTE: Vacuum any shavings.e) FeedPowerOutletwiringthroughhole,positionandattach

MountingPlatewith3/4"Drillerscrews.f) PositionandfastenPowerOutlettoMountingPlate.

Power Center/Inverter Frame (Figure 6)Removeinsulationcoveringfloorareaofrearpassengerstoragecompartment.IMPORTANT: Lay out all components in compartment to ensure correct location and clearances prior to drilling.a) PositionInverterMountingFrameagainstfarwall,sothat

mountingboltsclearanybeamsorwireharnessesbeneathit.AlsopositionFloorCablePass-ThroughPlateinfrontofInverterMountingFrame,onfloor,neartheSolenoidSwitchandoverlapBatteryTraypartsandmarkholesfordrilling.

b) Drill1/4"holestoaffixInverterMountingFrameandBatteryTraystofloorofrearpassengerstoragecompartment.Use2-1/2"holesawtocutoutareaforbothholesoftheFloorCablePass-ThroughPlate.NOTE: If your vehicle has metal flooring do not drill and use 3/4" Driller screws instead of bolts in next step.

c) SiliconearoundeachdrilledholeandboltdownInverterMountingFrame,BatteryTraysandFloorCablePass-ThroughPlate.

d) FitgrommetsaroundholesinFloorCablePass-ThroughPlate.

6d, 6e

4a

6c

4g

4a4a

4d

Grommet

Grommets

6d

7c.4, 7c.5

Cabling Installation (Figure 7) CRITICAL: Keep cable routing as far away from heated turbo charger as possible!a) Runandzip-tiethe178"PowerCablesatonefootintervalsfrom

AlternatororTruckBatteryBanktopassengercompartmentandfeedupthroughFloorCablePass-ThroughPlate.IMPORTANT: DO NOT yet hook up Red 178" Fused Positive Cable! That will be done last. Black 178" Negative Cable 3/8" weatherized end can be hooked up now. When zip-tying allow for 7-8 inches of slack for motion in air cussion cabs. Zip-tie both sides of the Positive Cable fuse to secure the connection.

b) PlaceRubberBatteryMatsinBatteryTraysandinstallbatteriesinBatteryTrayskeepingallpositivefacingtowardoutsideofcabandplaceRubberBatterySpacersbetweenbatteriestoreducefriction.

c) CAUTION: Be sure not to touch any of the battery terminals. A wrench with an insulated handle is highly recommended. Discard Nuts from batteries and use Battery Post Clamp Nuts to ensure the nuts are locked down and cannot vibrate loose. Connectcablingasfollows:1) AffixRed178"FusedPositiveCabletotheSolenoid.2) HookupRed15"PositiveCablethreeinarowtoBattery

BankOne.3) HookupBlack43"NegativeCablethreeinarowtoBattery

BankOneandattachlongendtoInverter.4) AttachshortendofRed48"PositiveCabletoSolenoid

andtightencontrolwirestoSolenoidthenconnectsecondconnectiontoInverterandlongendtoBatteryBankOne.

5) InstallSolenoidCoveronSolenoid.6) HookupRed104"PositiveCablethreeinarowtoBattery

BankTwoandruncableovertoconnecttoBatteryBankOne.7) HookupBlack104"NegativeCablethreeinarowtoBattery

BankTwoandruncableovertoconnecttoBatteryBankOne.8) FastenBatteryHold-downBars.9) AttachRed178"FusedPositiveCabletoAlternatororTruck

BatteryBank.10)CoverpositivesidesofBatteryBankswithRubberBattery

CoversandziptietotheBatteryHold-downBars.

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7a, 7b

FuseAlternator

7a7b

7b

7c.1

7c.1, 7c.2, 7c.3

7c.3Solenoid

7c.5

7c.7

7c.6, 7c.7, 7c.8

7c.6

Airbox

BatteryTray 1

BatteryTray 2

Inverter

Shore Power

Thermostatic Controller

Power Outlet

Heater

Exhaust Vent

7c.2

Driver Compartment

Passenger Compartment

7c.7

7c.6

7c.8 7c.8

7c.4

Control Box Installation (Figure 8)TheControlBoxwillbemountedinsidethepassengerstoragecompartment.EverythingwillbepluggedintoControlBoxforpowerdistribution.(See Figure 8)a) PositionpaperControlBoxtemplateandmarkonfrontof

passengerstoragecompartmentinterioraccess.b) DrillFanportwith4-1/2"holesaw,3/8"holesforresetbuttons

and1/4"mountingholesinpassengerstoragecompartment.c) FitgrommetaroundfanportedgeandaffixControlBoxtointerior

wallofpassengerstoragecompartmentwithbolts.d) RemoveControlBoxaccesspanelandrunthefollowingcablesto

theControlBox,feedupthroughbottomaccessportandplugintotheircolorcodedconnections:1) Airboxcablewithsevenwires-ACPower(black,white,

green),Exhaust(red,whitew/brownstripe),andBlower(orange,blue).

2) ShorePowerCable(black,white,green).3) PowerOutletPowerCable(black,white,green).4) ThermostatControllerCableintotheModJack.5) InverterPowerOutputCable(black,white,green).6) HeaterPowerCable(black,white,green).7) InverterPowerSwitchCable(red,black).8) SolenoidPowerCable(red,black).

e) AffixGroundStrapfromControlBoxtonegativeofInverterandreplaceControlBoxaccesspanel.IMPORTANT: Do not block air flow of fan.

f) DrillFanExhaustportinfrontofdriverstoragecompartment.g) MountAirflowGrilloverFanExhaustport.

Congratulations! YouhaveinstalledtheComfortCabAPUQuestions/Troubleshooting Call616-454-2616

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8 8a

Control Box

8b

8c

8f

8e

Grommet

SHORE

OUTLET

INVERTER

AIR

HEAT

THERMOSTAT

EXHAUST BLOWER

INV-SW SOLENOID

8d.1, 8d.2, 8d.3, 8d.4, 8d.5,8d.6, 8d.7, 8d.8, 8d.9

8g

8d.2

8d.6

8d.5

8d.1

8d.3

8d.4

8d.7 8d.8

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

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Ground Strap

8e