Bergstrom NITE Plus 9000i Installation Manual

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Installation Manual

Model 9000i Post June 2002

2390 Blackhawk Road ● P.O. Box 6007 ● Rockford, IL 61125 ●

● 1-866-204-8570

www.nitesystem.com

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Summary of Contents for Bergstrom NITE Plus 9000i

Page 1 Installation Manual Model 9000i Post June 2002 2390 Blackhawk Road ● P.O. Box 6007 ● Rockford, IL 61125 ● ● 1-866-204-8570 www.nitesystem.com...
Page 2: Table Of Contents
NITE Plus Installation Procedures Table of Contents Introduction Before You Start Parts List Tools Re q uired Installation Procedures Electrical Installation Espar Heater Webasto Heater Checklists International 9000i (post-June 2002) rev 10/7/2013...
Page 3 4 to 6 hours of driving. Add it all up, and you have a revolutionary no-idle system that will save you money and fuel year after year—the NITE Plus from Bergstrom. International 9000i (post-June 2002) rev 10/7/2013...
Page 4: Before You Start
NITE Plus Installation Procedures Before You Start A typical installation of the NITE Plus generally takes between 8 to 10 hours, although your particular situation may vary. This manual contains step-by- step installation instructions. It is divided into four categories: ●...
Page 5: Parts List
NITE Plus Installation Procedures Parts List Bergstrom Part Description Quantity Bergstrom Part # Bergstrom Bergstrom Part # 1000113877 NITE STANDARD KIT A/C ONLY Bergstrom Bergstrom 585414 1000078163 ASSEMBLY, NITE UPGRADE UNIT Bergstrom Bergstrom Bergstrom 1000014440 KIT, NITE POWER Bergstrom Bergstrom...
Page 6 NITE Plus Installation Procedures Parts List Bergstrom Part Description Quantity Bergstrom Part # Bergstrom Bergstrom Part # 1000014440 NITE Plus POWER KIT 585414 Bergstrom Bergstrom 660706 ASSY, WIRE BATTERY CABLE 5300MM BLACK Bergstrom Bergstrom Bergstrom 660707 ASSY, WIRE BATTERY CABLE 5000MM RED...
Page 7 NITE Plus Installation Procedures Tools Required Drill Bit Set Hole saws (1″, 1-5/8″, 2″, 2-1/2″ and 4-3/4″ ) Electric/Air Drill Screwdrivers/Assorted Bits (Flat Head & Phillips Head) Impact Gun Air saw/Jigsaw (Cutting Sheet metal) Torx Head (T30) Bit Metric Wrenches SAE Wrenches 10) 1/4″, 3/8″...
Page 8 NITE Plus Installation Procedures Prepare the Work Area Set up your work light, clear the sleeper compartment of loose items, and remove the divider curtain if there is one. Then remove the mattress and set outside the cab. Raise Bunk Lid and Remove Tray Remove and discard the tray.
Page 9 NITE Plus Installation Procedures Remove Wires Open wire supports and remove wires. Remove Bunk Cylinders Remove cylinders from lower support bracket and drill out rivets. Remove Center Bunk Support Now remove center bunk support. International 9000i (post-June 2002) rev 10/7/2013...
Page 10 1-10 NITE Plus Installation Procedures Remove Aluminum Floor Plate Carefully remove the screws holding the aluminum floor plate in place, then lift up and remove the floor plate. Set it outside the cab. Install the Mounting Plate Take the NITE Plus mounting plate with the pre-cut recirculation grills, and set it in the space where the previous floor plate was.
Page 11 1-11 NITE Plus Installation Procedures Remove Original Bunk Support Remove the bunk original support (A). Save the allen head nuts (B) to use with the NITE Plus bunk supports. Mark Area to be Cut for NITE Plus Duct Before cutting – Relocate wiring under the bunk next to the hinge !!! Locate the bottom support bracket (A) provided in your NITE Plus kit.
Page 12 1-12 NITE Plus Installation Procedures Cut Notch in Bunk for NITE Plus Duct Before cutting – Relocate wiring under the bunk next to the hinge !!! Raise bunk and locate the wires (A) under the area marked to be cut out in the previous step.
Page 13 1-13 NITE Plus Installation Procedures Ream Holes in NITE Plus Support Before installing the new support brackets, slightly ream the holes indicated by the circle in the picture. Install Top and Bottom Brackets First install the bottom bracket. Reinstall hinge and bottom bracket using the screws (A) removed in an earlier step.
Page 14 1-14 NITE Plus Installation Procedures Install T-duct Mounting Bracket on NITE Plus Unit Attach the T-duct mounting bracket to the back of the NITE Plus unit. You will need to remove 3 screws (A) and loosen the 4th one (B), then re-tighten the 4 screw to attach the bracket.
Page 15 1-15 NITE Plus Installation Procedures Attach Mounting Brackets Attach each corner of the NITE Plus unit to the aluminum mounting plate using the four mounting foot brackets. Fasten the brackets with the supplied screws and washers. Tighten securely. Reinstall Bunk Support Cylinders It is necessary to rotate the passenger’s side top support bracket 180 degrees to gain clearance when closing the bunk.
Page 16 1-16 NITE Plus Installation Procedures Reinstall Center Support Wall Attach Recirculation Duct to Unit Slide duct through duct opening from the front (A). Rear flange of duct (B) should slide under the same screws as the NITE Plus duct mounting bracket. Now tighten the 3 screws at the back of the duct.
Page 17 1-17 NITE Plus Installation Procedures Attach Gasket to Top of NITE Plus Duct Bracket Take the supplied gasket and remove the center section. Pull off backing to expose sticky side. Place gasket, sticky side down, onto the T-duct mounting bracket as pictured.
Page 18 1-18 NITE Plus Installation Procedures Attach Control Panel to Duct Push wiring behind duct, and mount the control panel to the duct using ¾” black Phillips head screws through the pre- drilled holes. Tighten carefully. When finished make sure switch is in the off position! Run Wiring behind Duct Place the wiring harness along the...
Page 19 1-19 NITE Plus Installation Procedures Attach Bottom of Duct to Unit Use one 1” 5/16 self-tapping screw. Drive screw through the small lip toward the bottom of duct for the most secure connection. Attach Vents to NITE Plus Duct Snap the louvered vents into each of the duct openings—no screws are necessary.
Page 20 1-20 NITE Plus Installation Procedures Install the NITE Plus Unit Power Harness Take the power harness and place the protective split plastic loom around it. Choose a convenient location to drill a 2″ hole for wiring. Attach provided grommet to hole to protect cables (A). Run the cables from the NITE Plus unit, down through the frame rails to the NITE Batteries.
Page 21: Installation
NITE Plus ® SECTION 2 ELECTRICAL INSTALLATION...
Page 22: Electrical Installation
Electrical Installation NOTE: Bergstrom does not condone putting batteries under the sleeper bunk. The floor is not designed to carry that amount of weight and even deep cycle AGM batteries can emit gas under certain circumstances. Bergstrom can only support batteries being placed in battery boxes or tool boxes designed to support the weight of the batteries outside the cab of the truck.
Page 23 Electrical Installation Attaching Hold-down Brackets Set two batteries side-by-side in the battery box and place a hold-down bracket on top, with the u-channel facing up. Take two 5/16″ bolts, place a 5/16″ flat washer on each, and then put the bolts through the outer holes.
Page 24 Electrical Installation Directions for Wiring a 6-Volt Series/Parallel, 4 Battery NITE Plus Step 1: Install the two short battery Then loom it. Use this cable to connect cables provided in the kit. These cables the positive (+) of one bank of batteries connect the positive (+) of one battery to the positive (+) of the other bank of batteries.
Page 25 Electrical Installation...
Page 26 Electrical Installation Directions for Wiring A 12-Volt Parallel, 4 Battery NITE Plus Parallel is all positives connected together and all negatives connected together. Step2: For the negative to negative Step 1: For the positive (+) to positive connections repeat procedure using (+) parallel connections measure and black cables.
Page 27 Electrical Installation...
Page 28 Electrical Installation Connect Separator to the Truck Batteries Add ring terminals and protective looms to ONE END of the negative and positive cables, leaving about an inch of the cables exposed for proper identification. DO NOT CUT cables at this time…you will do that in a later step.
Page 29 Electrical Installation Heater Installation Connect NITE Plus positive power cable to auxiliary battery location. Before connecting positive cable make sure blower control switch is in OFF position. Install 100 amp fuse between power cable and AGM positive battery post as shown. Do not tighten posts at this time.
Page 30: Espar Heater
NITE Plus ® SECTION 3 ESPAR HEATER INSTALLATION...
Page 31 Espar Heater Installation Unpack Heater Parts Take out the parts to the heating unit. NOTE: Do NOT use NITE duct or OE ductwork for heater venting. Prepare Heater Mounting Location Choose the most appropriate location to install the heater—in this case we have chosen a side box floor location.
Page 32 Espar Heater Installation Drilling Outlet Hole for Heat Unit Mark the floor of the truck using the 5 small holes of the mounting plate. Remove mounting plate, place a 4 ¼″ hole saw over the middle of the floor marks (A), and drill the outlet hole for the heater, intake, exhaust and pickup tube (B).
Page 33 Espar Heater Installation Heater Unit Assembly – Attaching Mounting Plate Snap end cap on heater unit (A). Place mounting plate over heater unit (B). Attach with flat lock washers and 10mm lock nuts— tighten down securely. Heater Unit Assembly – Attach Gasket and Fuel Line Connection Peel off backing from gasket and place gasket over mounting plate edges, sticky-side down.
Page 34 Espar Heater Installation Heater Unit Assembly – Identify Intake and Exhaust Ports Look closely at the two small metal tubes. One has an arrow pointing out away from the unit—this is the exhaust. One has an arrow pointing in towards the unit—this is the intake.
Page 35 Espar Heater Installation Prepare to Mount Unit Check to make sure truck batteries are still disconnected. Carry unit into truck. It will be mounted over the 4 ½″ hole that was drilled earlier. Make sure hoses and tubes don’t get tangled or caught on anything.
Page 36 Espar Heater Installation Attach Heat Line to Sleeper Vent Take the black metallic flex tube, measure and cut length to run from heater unit to louver/vent opening (A). Place two clamps over ends of tube, and clamp tube to heating unit and louver. Tighten clamps securely but do not over tighten.
Page 37 Espar Heater Installation Attach Template to Faceplate – Drill Take the sticker template that came with the Espar controller and place it on the panel. Drill holes through panel for wiring and for attaching screw as indicated on sticker. Pull sticker off after holes have been drilled.
Page 38 Espar Heater Installation Install Connector on Mini Controller Harness Connect ends of wire harness to plastic connector in this way: 1 = red, 2 = yellow, 3 = brown, 4 = solid grey, 5 = yellow with violet stripe. Attach Wire Connector from Heater Control Harness Route the control cable along the bed towards the heater control panel.
Page 39 Espar Heater Installation Finishing Intake and Exhaust Hose Installation First, attach intake air tube to truck structure with zip ties. Put cap on bottom of intake tube. Next, run exhaust hose toward back of cab (A), attach with clamps to the structure of the truck.
Page 40 3-10 Espar Heater Installation Drill Hole in Fuel Tank, Insert Pickup Tube and Mount Fuel Assembly Use a 1″ hole saw to scribe initial location for two outer holes. Drill the two outer 1/4″ holes centered on scribe. Then complete drilling the 1″...
Page 41 3-11 Espar Heater Installation Run Heater Unit Power Cable to NITE Plus Batteries Take the heater unit power cable, run it under the truck (attach with zip ties where necessary) over to the NITE Plus batteries. Strip back outer cover to expose two inner wires.
Page 42: Webasto Heater
NITE Plus ® SECTION 3 WEBASTO HEATER INSTALLATION INSTALLATION...
Page 43 Webasto Heater Installation DO NOT USE NITE DUCT FOR HEAT VENT. ATTN: Refer to Webasto manual for all heater installation instructions. http://techwebasto.com/redirect/heater_main/5001118B.pdf 2390 Blackhawk Road • P.O. Box 6007 • Rockford, IL 61125 • • 1-866-204-8570 www.nitesystem.com...
Page 44: Checklists
NITE Plus ® SECTION 5 CHECKLIST...
Page 45 Checklist Now that you’ve completed installation, it’s time to check the systems to make sure everything is working properly. To help you do that, we’ve prepared a brief description of how the NITE Plus operates, and several checklists to help you make sure everything is in working order.
Page 46 Checklist 2. System components checklist Follow this table to check that the individual components of the NITE Plus run properly when the unit is ON. Component Function How to check it Blower (evaporator) Blows cold air to the sleeper Switch the NITE Plus control area through the ducting.
Page 47 Checklist 3. Electrical and temperature checklists Use the following checklist to check that your NITE Plus is operating within the correct electrical and temperature ranges. Electrical power 3.1 Check the NITE Plus unit’s voltage. On the power supply cables (red and black cables) located close to the unit, there is a black connector from which the voltage can be read.
Page 48 Checklist 4.3 Check voltage with engine OFF First, check that the voltage on the TRUCK batteries is the same as the voltage on the separator (use the ground terminal to check separator voltage). Both voltages should be approximately 12V. Next, check that the voltage on the aux batteries is the same as the voltage on the separator (use the ground terminal to check separator voltage).

This manual is also suitable for:

1000113877 1000119244 1000113987 1000014440