Issued: 09/15/06 Catalog: C-267 MFG Code: HTR Publié: 09/15/06 Catalogue: C-267 Code de ligne: HTR Publicar: 09/15/06 Catálogo: C-267 Codigo FAB: HTR Engine Heater Application Guide Guide d'application pour chauffe-moteurs Guía de Aplicación de Calefacción de Motor 2006-07
ELEMENT MUST FACE IN THIS DIRECTION TO AVOID CONTACT WITH ENGINE WALL HEATERS MANUFACTURED TO REPLACE FROST PLUG IN THE BLOCK OF AN ENGINE RECOMMENDED LOWER RADIATOR HOSE HEATER FREEZE PLUG HEATER DIRECTION PERMANENT REMOVABLE LOCATION WATTS WIRE LEADS ARE PERMANENTLY ATTACHED TO HEATING ELEMENT RECOMMENDED EXTERNAL TANK HEATER HOW TO USE THIS APPLICATION GUIDE WIRING WITH SILICONE END IS PLUGGED INTO HEATER AFTER INSTALLATION LOWER RAD HEATER EXTERNAL HEATER 12010 K9 WATTAGE OF RECOMMENDED HEATER
TABLE OF CONTENTS How to Use Application Guide Location of Block Heater Five Most Common Failure Problems Inside Front Cover Inside Front Cover Inside Front Cover PAGE 2-19 20-23 24-39 40-57 58-65 Automotive and Light Truck Applications Agricultural Applications Heavy Duty Truck Applications Industrial Application Ether Start Systems Installation and Information Freeze Plug Lower Radiator Hose Heater External Tank Heater Magnetic Heater Dipstick Heater 12-Volt Interior Heaters Silicone Pad Heaters Battery
AUTOMOTIVE & LIGHT TRUCK APPLICATION GUIDE FREEZE PLUG HEATER mm SIZE DIRECTION LOCATION CORD WATTS LOWER RAD HEATER EXTERNAL HEATER PG 70 79400 ACURA 4 CYLINDER 2006-04 2.4 1999-98 2.3 1997-95 2.2 2006-02 2.0 2001-90 1.8 2005-02 1.7 2005-90 1.7 2001-97 1.6 5 CYLINDER 1999-92 2.5 6 CYLINDER 2006-96 3.5 2003-91 3.2 2006-93 3.2 NSX 1999-91 3.0 NSX 2003-97 3.0 1990-87 2.7 Legend 1990-86 2.
FREEZE PLUG HEATER mm SIZE DIRECTION LOCATION CORD WATTS LOWER RAD HEATER EXTERNAL HEATER PG 70 79400 BMW (CONTINUED) 06 CYLINDER 1993-85 3.5 ALL 1998-97 3.2 24V 1984-78 3.2 533,633,&733 2006-01 3.0 2000-95 2.8 1991-82 2.7 325 & 528 1982-76 2.7 528 2006-92 2.5 325 & 525 1991-88 2.5 325 & 525 1986-84 2.4 Diesel 524 1995-92 2.0 325 & 525 79646 79646 79646 79646 79646 79646 78268 79646 79646 79646 79646 9 1 9 1 1 1 3 1 7 11 1 44.5 44.5 44.5 44.5 44.5 44.5 36 44.5 44.5 44.5 44.
AUTOMOTIVE & LIGHT TRUCK APPLICATION GUIDE FREEZE PLUG HEATER mm SIZE DIRECTION LOCATION CORD WATTS LOWER RAD HEATER EXTERNAL HEATER PG 70 79400 CADILLAC (CONTINUED) 6 CYLINDER 1985-84 4.3 Diesel 1984-80 4.1 2005-02 3.2 2002-00 3.0 1989-85 2.8 8 CYLINDER 2006-01 6.0 MPV 1996-90 5.7 1985-78 5.7 Diesel 1985-76 5.7 2005-01 5.3 MPV 1996-90 5.0 1992-86 5.0 1999-82 4.9 2002-82 4.5 1995-82 4.
FREEZE PLUG HEATER CHEVROLET mm SIZE DIRECTION LOCATION CORD WATTS LOWER RAD HEATER EXTERNAL HEATER PG 70 79400 (CONTINUED) 6 CYLINDER (CONTINUED) 1996-89 3.4 Conv. 2005-89 3.4 Transvers 1980-78 3.2 (196) 2003-89 3.1 Transvers 1996-89 3.1 Conv 1985-82 3.0 1996-93 2.8 1992-82 2.8 Conv 1992-82 2.8 Transvers 1984-80 252 1984-75 250 1974-68 250 1984-78 229, 200 8 CYLINDER 1999-91 7.4 1990-73 7.4 1994-82 6.5 Diesel 1994-82 6.2 Diesel 2006 6.0 1992-91 6.0 2005-74 5.7 LS6 2005-98 5.7 LS1 2005-98 5.
AUTOMOTIVE & LIGHT TRUCK APPLICATION GUIDE FREEZE PLUG HEATER CHEVROLET GMC TRUCK 6 CYLINDER (CONTINUED) 1985-82 231 1981-78 231 1982-78 229, 200 1995-84 W7H, W7T Forward Tiltmaster 1995-84 W4,W5,W6,W7 Forward Tiltmaster 8 CYLINDER 2006-00 8.1 2002-91 7.4 1990-69 7.4 1997-90 7.0 2006-01 6.6 Diesel Duramax 2002-93 6.5 Diesel 1993-82 6.2 Diesel 2006-98 6.0 LQ4 2006-90 6.0 LQ9 2002-99 5.7 LS1 2006-98 5.3 LM7 2006-98 4.8 LR4 1996-94 4.
FREEZE PLUG HEATER mm SIZE DIRECTION LOCATION CORD WATTS LOWER RAD HEATER EXTERNAL HEATER PG 70 79400 DODGE TRUCK 4 CYLINDER 1990-84 2.6 Thru 1983 2.6 2002-87 2.5 2004-87 2.4 1985-83 2.3 DIESEL 1997-82 2.2 1991-83 2.0 1982-78 2.0 1996-92 1.8 6 CYLINDER 2006-98 5.9 6BTCummins 1997-89 5.9 Cummins 2004-89 3.9 2006-87 3.8 2006-02 3.7 2006-87 3.3 1999-88 3.0 1987-61 225,198,170 8 CYLINDER Thru 2003 5.9 2003-91 5.2 2006-00 4.7 1992-65 All V8’S 10 CYLINDER 2004-94 8.0 2006-05 8.
AUTOMOTIVE & LIGHT TRUCK APPLICATION GUIDE FREEZE PLUG HEATER FORD MOTOR CO. 4 CYLINDER (CONTINUED) 1985-83 2.2 Perkins Diesel 1996-95 2.0 14 Probe 2004-97 2.0 Zetec 2006-95 2.0 1988-83 2.0 1987-84 2.0 Diesel 1974-72 2.0 1996-91 1.9 1990-81 1.9 1996-91 1.8 1997-88 1.6 1987-81 1.6 1980-71 1.6 96.6CID 1998-88 1.3 1990-71 1.3 6 CYLINDER 1995-90 4.9 1997 4.2 2006-05 4.0 2005-82 3.8 Conv 1996-88 3.8 Transverse 1998-96 3.4 SHO 1994-89 3.2 2006-00 3.0 Duratec 1999-93 3.0 SHO 2006-86 3.0 1991-86 3.0 1990-86 2.
FREEZE PLUG HEATER FORD TRUCK mm SIZE DIRECTION LOCATION CORD WATTS LOWER RAD HEATER EXTERNAL HEATER PG 70 79400 (CONTINUED) 4 CYLINDER (CONTINUED) 1983-72 2.0 2000cc 1983-72 1.8 1800cc 6 CYLINDER 1989-86 7.8 Diesel 1989-86 6.6 Diesel 1997-65 4.9 2003-96 4.2 2005-98 4.0 2003-90 4.0 OHV 1997-65 3.9 2003-95 3.8 1996-82 3.8 2002-99 3.3 Villager 1999-93 3.0 Villager 2003-86 3.0 Inc Aerostar 2006-01 3.0 Duratec 1992-86 2.9 1986-83 2.8 1983-64 250,200,170,144 8 CYLINDER 1998-64 7.5 2003-93 7.
AUTOMOTIVE & LIGHT TRUCK APPLICATION GUIDE FREEZE PLUG HEATER HONDA mm SIZE DIRECTION LOCATION CORD WATTS LOWER RAD HEATER EXTERNAL HEATER PG 70 79400 (CONTINUED) 4 CYLINDER 1992-84 1.3 1992-84 1.5 2000-88 1.6 1987-79 1.6 1999-88 1.5 2006-03 1.3 6 CYLINDER 2006-98 3.5 2005-94 3.2 2006-98 3.0 1996-95 2.
FREEZE PLUG HEATER mm SIZE DIRECTION LOCATION CORD WATTS LOWER RAD HEATER EXTERNAL HEATER PG 70 79400 ISUZU 4 CYLINDER ALL 4BD1 1995-88 2.6 1995-85 2.3 2002-98 2.2 1986-82 2.2 Diesel 1988-81 2.0 1988-81 1.9 1993-81 1.8 1985-81 1.8 DIESEL 1993-90 1.6 1989-85 1.5 1985-82 1.1 116CC 6 CYLINDER 1993-89 6.5 1993-89 5.8 1993-89 4.8 2006-04 4.2 2004-92 3.2 1993-91 3.1 1991-89 3.1 1993-89 2.
AUTOMOTIVE & LIGHT TRUCK APPLICATION GUIDE FREEZE PLUG HEATER mm SIZE DIRECTION LOCATION CORD WATTS LOWER RAD HEATER EXTERNAL HEATER PG 70 79400 LEXUS 2006-99 2006-04 2004-93 1992-91 1992 1991-90 4.7 3.3 3.0 2JZ-GE 3.0 Transverse 3.0 CONV 2.
FREEZE PLUG HEATER mm SIZE DIRECTION LOCATION CORD WATTS LOWER RAD HEATER EXTERNAL HEATER PG 70 79400 MERCEDES ALL ALL 230 Gas Diesel 1984&Newer 78281 78281 THD THD 38 38 Right Right 78064 78064 400 400 78161 NO 79402/78237 79402/78237 NO NO 78084 78289 78084 78291 78291 78091 78291 78291 78091 78091 3 3 9 9 3 3 3 4 9 12 40 35 40 35 35 35 35 35 35 35 RR FC LR 2nd LR LR 79786 79786 79786 79786 79786 79786 79786 79786 79786 79786 400 400 400 400 400 400 400 400 400 400 78162 NO NO NO
AUTOMOTIVE & LIGHT TRUCK APPLICATION GUIDE FREEZE PLUG HEATER mm SIZE DIRECTION LOCATION CORD WATTS LOWER RAD HEATER EXTERNAL HEATER PG 70 79400 NISSAN TRUCK 4 CYLINDER 1988-81 2.5 Diesel 2004-90 2.4 1989-81 2.4 1989-81 2.2 1983-81 2.2 Diesel 1989-81 2.0 1989-82 2.0 Transverse 1989-82 2.0 Conv 1980-74 2.0 1976 2.0 1952cc 1980-74 1.8 1973-70 1.6 6 CYLINDER 2003-01 3.5 2002-91 3.3 Conv 2004-99 3.3 Trans 1997-84 3.0 Conv 1997-93 3.0 Transverse 8 CYLINDER 2006-04 5.
FREEZE PLUG HEATER mm SIZE DIRECTION LOCATION CORD WATTS LOWER RAD HEATER EXTERNAL HEATER PG 70 79400 OPEL 1978-76 1877 78291 12 35 LF 79786 400 78161 79401/79886 NO 3 9 9 3 3 3 3 6 3 —— 3 3 6 3 6 5 12 6 6 12 6 6 40 40 40 41 41 35 40 41 35 35 35 40 35 36.
AUTOMOTIVE & LIGHT TRUCK APPLICATION GUIDE FREEZE PLUG HEATER PONTIAC mm SIZE DIRECTION LOCATION CORD WATTS LOWER RAD HEATER EXTERNAL HEATER PG 70 79400 (CONTINUED) 6 CYLINDER 1987-85 4.3 1985-82 4.3 Diesel 2006-05 3.9 2002-96 3.8 Firebird 2006-93 3.8 Transverse 1992-86 3.8 Transverse 1988-80 3.8 2006-05 3.5 2006-93 3.4 Transverse 1997-90 3.4 Conv 1992-88 3.4 Transverse 1999-93 3.3 Transverse 1992-89 3.3 2002-93 3.1 Transverse 1997-90 3.1 Conv 1992-87 3.1 Transverse 1992-87 3.1 APV 1989-82 3.
FREEZE PLUG HEATER mm SIZE DIRECTION LOCATION CORD WATTS LOWER RAD HEATER EXTERNAL HEATER PG 70 79400 SAAB 4 CYLINDER 2005-90 2.3 1993-85 2.1 1984-75 2.1 1993-85 2.0 1984-75 2.0 6 CYLINDER 2004-99 3.0 78081 78226 78276 78226 78276 9 THD 3 THD 3 36 26 41.5 26 41.5 LF —— RR —— RR 79786 78064 79786 78064 79786 400 400 400 400 400 NO NO NO NO NO NO NO 79401/79886 NO NO NO NO NO NO NO 78284 THD 28 —— 79680 400 NO NO NO 78075 79850 THD 4 28 42.
AUTOMOTIVE & LIGHT TRUCK APPLICATION GUIDE FREEZE PLUG HEATER TOYOTA mm SIZE DIRECTION LOCATION CORD WATTS LOWER RAD HEATER EXTERNAL HEATER PG 70 79400 (CONTINUED) 6 CYLINDER 2006-04 3.3 2004-94 3.0 1MZ-FE 1993-92 3.0 3VZ-FE 1992-86 3.0 7M-GE 1992-86 3.0 7M-GE,7M-GTE 1988-86 3.0 7M-GE 1999 3.0 1MZ-FE 1992-86 2.8 5M-GE 1985-80 2.8 5ME,5ME-GE 1985-79 2.6 4ME 1979-71 2.6 4M 1991-88 2.
FREEZE PLUG HEATER mm SIZE DIRECTION LOCATION CORD WATTS LOWER RAD HEATER EXTERNAL HEATER PG 70 79400ˆ VOLKSWAGEN TRUCK 1991-84 1991-84 1995-92 2.1 Vanagon 1.9 Vanagon 2.5 Euro Van 79753 79753 79747 ------- ------- Clamp On Clamp On Clamp On ------- ——— 78084 78084 78278 78278 —— 9 6 3 3 40 40 44.5 44.5 —— RF RF RR RR —— 79786 79786 79786 79786 78278 78274 78274 78084 9 9 9 6 44.5 36 36 36.
Agricultural Applications Frost Plug Watts Location Direction Lower Radiator External Tank 78262 600 RR 12 78163 79403/78238 XP170, XP190 78163 79403/78238 XP180, XP210, XP220 78164 79403/78238 78162 79403/78238 78162 79403/78238 Diameter ALLIS CHALMERS 170 Diesel 7030,7040,7045,7050 7060,7080,7580 W,WC,WD,WF,WR 79865 1500 1" RR THD 180, 185, 200, 7000, 7010, 7020 78989 1000 Plate RR 78309 or 78313 400 3/4" NPT RF THD 400 1" NPT RF THD 79403/78238 BELARUS 500,800
Frost Plug Watts Diameter Location Direction V1100B 78309 400 3/4" NPT RS THD 79402/78237 V2203 78934 400 1 3/8" RF 12 79402/78237 78265 600 1 3/4" RS 12 79402/78237 78309 400 3/4" NPT CASE Lower Radiator External Tank (CONTINUED) CATERPILLAR 1140,1145,1150, 1160,3206 COCKSHUTT 500 Hercules 560 Perkins 79402/78237 FORD 2000,3000,4000 5000,6000 Pre 1968 3000,4000,5000, 6000,9000 (1968-70) 3000,4000,5000,7000 8000,9000 Since 1970 8000,9000 78163 79402/78237 78265 600 1
Agricultural Applications Frost Plug Watts Diameter Location All 50,60,70,730,3029 Series A,B,D,&G 520,560,630,720,730 820,830,A,B,G Thru 1982 2010 78309 400 3/4" NPT THD 3020,4000,4320.
Frost Plug MASSEY FERGUSSON Watts Diameter Location Direction Lower Radiator External Tank 78163 79402/78237 (CONTINUED) 3150,3160.
Heavy Duty Truck Applications Make & Model Part No.
Installation Information ALLIS CHALMERS Replaces 1" pipe plug on right rear of block Replaces 1" pipe plug in oil cooler Replaces right rear frost plug CATERPILLAR Replace Plug in right rear of oil cooler Replaces 1" plug in oil cooler Replace plug in rear of cooler Replaces front frost plug Replaces water inspection plate on left side of engine 1670 G & D33 Replaces water inspection plate on side of engine RR 3 O’clock Replaces water jacket access plate on side of engine Install in 1 1/2" frost pl
Heavy Duty Truck Applications Make & Model CATERPILLAR Part No.
Installation Information CATERPILLAR Replaces 3/4" pipe plug on right rear side of engine Replaces 1" pipe plug in oil cooler 3204: replaces right rear frost plug 3208: replaces center frost plug on each side of engine—2 required Replaces 3/4" pipe plug on rear of oil cooler on left side of engine. Hold element stationary while tightening adapter. 3176: replaces 3/4" pipe plug on right front of engine. 3304/3306: replaces pipe plug in water jacket on left side of engine.
Heavy Duty Truck Applications Make & Model CUMMINS Part No.
Installation Information CUMMINS Rear of engine block Replaces front water jacket plate on side of engine 1.
Heavy Duty Truck Applications Make & Model Watts Volts Diameter 79862 1500 120 Plate Cordset: 120V 78064 ISX, QSX, Signature 600 79206 1500 120 Plate Cordset: 120V 78064 240V 78751 V903, VT903, VT350 Formula VT300 (902 CID) V6-195, 200, 215, 280 (588 CID) V8-235, 265, 300, 370 (785 CID) 350 & 430 (950 CID) 78214 79927 1500 1500 120 240 V903, VT903, VT350 Formula VT300 (Alternative installation.
Installation Information CUMMINS RR Replace two bolt plate at front of engine on right side Replacement element only Replaces 3/4" plug on bottom rear of oil cooler DETROIT DIESEL Replaces water jacket plate on side of engine Replaces water jacket plate on side of engine Replaces water jacket plate on side of engine Replaces water jacket plate on side of engine Replaces water jacket plate on side of engine Replaces water jacket plate on left front cyl.
Heavy Duty Truck Applications Make & Model DETROIT DIESEL Part No.
Installation Information DETROIT DIESEL Replaces pipe plug in front face of cyl. bank on driver’s side or pipe plug in oil cooler elbow pipe. Pipe bushing may be required. Pipe plug not available on all engines. RS 1 1/2" frost plug on right front Engines built prior to September 1993 Replaces 3rd or 4th frost plug on left side of engine. Engines built after Aug.
Heavy Duty Truck Applications Make & Model FORD Part No. Watts Volts Diameter Service Parts (CONTINUED) 6.6L, 7.8L, 1986-89 80053 78677 1500 1500 120 240 1 1/2" Cordset 120V 79857 8 cyl. 6.9L, 7.3L Diesel 1993 to Present 78303 400 120 1 1/2" Alternate Navistar Installation 79713 1000 120 3/4" NPT Cordset 120V 78786: 120V 78064 8 cyl. 6.9L, 7.
Installation Information FORD Replaces 2nd frost plug from rear, right side 2 heater units recommended. Install LR & RR at 12:00 Install in oil cooler Replaces right rear frost plug w/element at 11:00 GMC Install in front frost plug on either side— element at 12:00 Install on right side—element at 9:00 Install in center frost plug on left side— element at 12:00 Install on right side—element at 9:00 HINO Replaces 3/4" pipe plug.
Heavy Duty Truck Applications Make & Model Part No. Watts INTERNATIONAL—NAVISTAR (CONTINUED) Volts Diameter Service Parts 9L DT550 MV 404, 466, 485, 537 78279 600 120 1 1/2" Disk Type Cordset 120V 79786 V800 (789 CID) 78413 78640 1500 1500 120 240 1" NPT Cordset: 120V 78064 240V 78751 817 78181 78655 1500 1500 120 240 1 3/4" Cordset 120V 78064 240V 78751 806, 1206 w/0282 Eng.
Installation Information INTERNATIONAL—NAVISTAR Replaces any frost plug—point element between cyl. Replaces 1" pipe plug on oil cooler bonnet Install in right side frost plug 1, 2, or 5— element at 6:00 Install in 3rd or 4th frost plug on left side of engine element at 1:00 IVECO Right rear of engine of head JOHN DEERE Replaces 3/4" pipe plug on rear face of engine. Some engines may require a 1" x 3/4" pipe reducer bushing.
Heavy Duty Truck Applications Make & Model Watts Volts Diameter 78181 78655 1500 1500 120 240 1 3/4" 78220 78772 1500 1500 120 240 1 3/4" E7 & EM7 79924 78740 1500 1500 120 240 Plate Cordset: 120V 78064 240V 78751 865, 866, & 1000 Series EM9-400 79713 78656 78184 78659 1000 1000 1500 1500 120 240 120 240 3/4" NPT Cordset: 120V 78064 240V 78751 EM6237-675 78220 78772 1500 1500 120 240 1 3/4" E-Tech 79188 1500 120 Plate Cordset: 120V 78064 79917 1000 120 60 mm Cordset 12
Installation Information MACK Replaces 1 3/4" frost plug on left side of engine Replaces 1 3/8" core plug on right side of block Installs in 3/4" NPT plug in oil cooler casting Use 2 heaters Install in 1 3/4" frost plug hole with smooth bore Mounts in water pump MERCEDES RR UD TRUCK RF 3 o’clock Replaces plate in center of oil cooler 6:00 RC 5:00 LR 12:00 LR 12:00 VOLVO Replaces 44mm threaded plug on left front of engine LR 39
Industrial Applications Frost Plug Watts Voltage Diameter Related Parts See Case in Agriculture Section CATERPILLAR 1404 78950 400 120 2 1/8" Cordset 120V 79786 3003 78091 400 120 35mm Cordset 120V 79786 3013, 3024, 3914 78084 400 120 40mm Cordset 120V 79786 3034 79653 400 120 50mm Cordset 120V 79786 3046 78926 600 120 35mm Cordset 120V 79786 For additional Caterpillar listings Heavy Duty section Page CONTINENTAL F162 78287 400 120 1 5/8" Cordset 120V 79786 F163 7
Installation Instructions LC 12 o’clock LF 6 o’clock LF 6 o’clock Rear face 4 o’clock LR 6 o’clock LS 12:00 LS 12:00 LS 12:00 LS 12:00 LS 12:00 LS 12:00 Install in oil cooler 41
Industrial Applications Frost Plug Watts Voltage Diameter Related Parts 78260 600 120 1 1/2" Cordset 120V 79786 KSG411, KSG416 67, 98 C.I.D. 78287 400 120 1 5/8" Cordset 120V 79786 091PV, GSG417 91, 104 C.I.D. 78305 400 120 1 1/2" Cordset 120V 79786 134, 172, 192 C.I.D. 78949 600 120 2.05" Cordset 120V 79786 LRG423, LRG425 79843 600 120 1 1/2" Cordset 120V 79786 LSG423, 140 C.I.D. 79678 600 120 1 1/2" Cordset 120V 79786 DSD442, ESD442, 254 C.I.
Installation Instructions RF 6 o’clock LF 12 o’clock RFF 9 o’clock LS 12 o’clock LR 3 o’clock LC 12 o’clock LC 12 o’clock RF 12 o’clock RF 12 o’clock RR Left Side Right side 6 o’clock 43
Industrial Applications Frost Plug FORD Watts Voltage Diameter Related Parts (CONTINUED) 8 CYLINDER WSG858 255, 302, 351W, C.I.D. 79678 600 120 1 1/2" Cordset 120V 79786 LSG861,870, 875 370, 429, 460 C.I.D. 79678 600 120 1 1/2" Cordset 120V 79786 401, 477, 534 C.I.D. 79714 1000 120 1 3/4" Cordset 120V 79786 For additional Ford listing see Heavy Duty section Page HERCULES G1600 2.7 163 C.I.D. 78950 400 120 2 1/8" Cordset 120V 79786 D2300, DT2300, D3400 since 1982 3.7 & 5.8& 5.
Installation Instructions RR 6 o’clock Right side 12 o’clock Front frost plug hole LC 12 o’clock RC 12 o’clock RD 12 o’clock Install in any available frost plug hole RF 10 o’clock LS 6 o’clock RF 10 o’clock LF 9 o’clock LS 9 o’clock 45
Industrial Applications Frost Plug ISUZU Watts Voltage Diameter Related Parts (CONTINUED) 4 CYLINDER 4FB1 111 C.I.D. 78077 400 120 1 3/8" Cordset 120V 78786 4HE1 79856 600 120 1 3/4" Cordset 120V 78786 4BB1, 4BD1, 6BD1, 6BG1, 6HE1, 6SA1, QD90, QD100, QD130, QD145 79313 600 120 1" NPT Cordset 120V 78064 78265 600 120 1 3/4" Cordset 120V 78786 78481 400 120 35 mm Cordset 4LE1, or 4LE2 4JB1, 456 120V 78064 78285 400 120 45 mm 4JG Cordset 120V 78064 6 CYLINDER 329 C.
Installation Instructions RR 12 o’clock RF 6 o’clock LR or Rear Face 1 o’clock LS 9 o’clock LR 6 o’clock FR 1 o’clock RS 6 o’clock Engines over 7L may require 2 heaters Rear 6 o’clock In oil cooler housing 47
Industrial Applications Frost Plug Watts Voltage Diameter Related Parts KOMATSU SA6D125 78220 1500 120 1 3/4" Cordset 120V 78064 S6D-95L, SA6D-95L 79853 600 120 1 9/16" Cordset 120V 79786 4D95 164 C.I.D.
Installation Instructions RS LR 12 o’clock LR 12 o’clock RR RR Back of Head LF Threaded hole RF 2 o’clock RF Threaded hole LF Threaded hole Rear Face RF 2 o’clock RF Threaded hole 49
Industrial Applications Frost Plug KUBOTA Watts Voltage Diameter Related Parts (CONTINUED) Z600, ZH600 78309 400 120 3/4" NPT Cordset 120V 78064 D905, DH905, D1005, DH1005, D1105, V1105, V1205, V1305, VH1305, V1505 78313 400 120 1" NPT Cordset 120V 78064 78925 400 120 1 1/4" Cordset 120V 79786 L3A 78084 400 120 1 9/16" Cordset 120V 79786 K3A, K3B 78286 600 120 4G32, 4G33 78946 400 120 1 3/8" Cordset 120V 79786 4G52, 4G53, 4G54 78272 400 120 50 mm Cordset 120V 7978
Installation Instructions LF Threaded hole RS 12 o’clock RR 9 o’clock RS 12 o’clock LS 12 o’clock RC 3 o’clock RR 11 o’clock LF 3 o’clock LR 3 o’clock RR 9 o’clock LR 51
Industrial Applications Frost Plug Watts Voltage Diameter Related Parts 78272 400 120 50 mm Cordset 120V 79786 H20-2, H25 (1.2, 1.5) 78946 400 120 35 mm Cordset 120V 79786 A12, A15, H20, SD22, SD4-47, SD25 (2.2) 78289 400 120 35 mm Cordset 120V 79786 TD42 78479 600 120 35 mm Cordset 120V 79786 MWM MURPHY D225 & D226 NISSAN 4 CYLINDER Z24 Cordset 120V 79786 78084 400 120 40 mm 6 CYLINDER Cordset 120V 79786 FD6 (5.6) 78084 400 120 40 mm Cordset 120V 79786 LD28 (2.
Installation Instructions LF 6 o’clock LR 12 o’clock RC LC 12 o’clock RF 3 o’clock LR 12 o’clock RF 12 o’clock LS 12 o’clock Front LF 6 o’clock 53
Industrial Applications Frost Plug PERKINS Watts Voltage Diameter Related Parts (CONTINUED) 03.12, 103.13, 103.15 78084 400 120 40 mm Cordset 120V 79786 3-152 78262 or 79855 600 120 1 1/4" 600 120 Bushing Cordset 120V 79786 120V 79858 104.19, 104.
Installation Instructions LF 6 o’clock 2nd from rear LS 6 o’clock LF 6 o’clock RC 12 o’clock RS 12 o’clock LS 12 o’clock LS 12 o’clock LS 12 o’clock 2nd from rear LS of block 12 o’clock LR 12 o’clock LS In head 4 o’clock RR 12 o’clock LR 12 o’clock RR 12 o’clock 55
Industrial Applications Frost Plug PERKINS Watts Voltage Diameter Related Parts (CONTINUED) 8 CYLINDER 8-540 78313 400 120 1" NPT Cordset: 120V 78064 8-640 78413 1500 120 1" NPT Cordset 120V 78064 5R, 2J (1.9, 2.5) 78272 400 120 50 mm Cordset 120V 79786 4Y (2.2) 78289 400 120 35 mm Cordset 120V 79786 2F (4.2) 78272 400 120 50 mm Cordset 120V 79786 3F 79653 400 120 50 mm Cordset 120V 79786 78270 400 120 36.
Installation Instructions LS & RS LR LF 12 o’clock LR 9 o’clock LR 9 o’clock LR 2 o’clock RC 6 o’clock 57
COLD WEATHER STARTING FLUID INJECTION SYSTEMS FAST, SAFE, DEPENDABLE — STARTS EVERY TIME Suitable for Diesel, Gasoline, and Gasohol Engines Pat. Nos. 3, 198, 404 and 3960131 and Foreign Patent K ATS was created and developed as a truly effective product for cold weather and hard starting problems. Owners and operators of diesel and gas operated equipment have long known that delayed starts and slow starts mean big money losses in labor, maintenance and operating revenue.
HOW THE KATS ETHER SYSTEMS OPERATE: T hese functional drawings provide a visual understanding of the operational characteristics of our Automatic Electric KATS Start. These features are particularly important to those looking for top quality and highly durable starting fluid systems.
KATS MODEL AUTOMATIC SERIES THE KATS SERIES IS A FULLY AUTOMATIC ELECTRIC OPERATED ETHER INJECTION SYSTEM. O ur most popular system combines the advantages of no operator control and thermostatic system control into Fast, Reliable, cold weather starts everytime. All this prevents pre-loading, overloading, and power boosting of the engine. The ether injection system will only operate at 50°F or below. See page 63 for thermostats that open at higher or lower starting temperatures.
KATS MODEL PUSH BUTTON SERIES THE KATS SERIES IS A PUSH BUTTON ELECTRIC OPERATED ETHER INJECTION SYSTEM. T he Push Button Series has all the great high quality features of the Automatic Series except the operator has “limited control” over the use of the system. Providing the engine temperature is at 50°F or below, the operator engages and releases the push button at the dashboard or suitable location, causing a 5 - 6 cc metered shot of Fast Flash Fuel to be injected into the engine manifold.
KATS MODEL PULL CABLE SERIES THE KAT'S SERIES IS A MANUALLY OPERATED ETHER INJECTION SYSTEM. T he Pull Cable Series is a fully operator controlled manual Ether Injection System. It’s designed to withstand even the toughest of cold weather conditions and applications. If the operator determines that any given “hard starting” situation exists, he/she can engage the Pull Cable to inject a metered shot of Ether Fuel to the engine.
COMPONENT PARTS AND ASSEMBLIES THE FOLLOWING COMPONENTS, PARTS, AND ASSEMBLIES CAN BE PURCHASED AS REPLACEMENT PARTS, OR AS STAND-ALONE ASSEMBLIES IF SO REQUIRED. ORDER BY PART NUMBER. ACTUATOR VALVE ASSEMBLY WITH MOUNTED CYCLING SWITCH Assembly includes Cycling Switch and Cycling Switch Socket. 12 or 24 Volt, 5-cc metering chamber, 6-8 Amps, 8” of 16 gauge wire leads, intermittent duty, 65-120 cycles per minute (CPM), straight valve fitting, gaskets, and protective valve plug.
DUAL NOZZLE ADAPTOR KIT NUT AND COMPRESSION SLEEVE KIT Valve T-fitting 1/8” Tube x 1/8 NPT, 4 feet nylon tubing (TBN005), compression nuts and sleeves. Converts single manifold ether injection to dual injection type. NOTE: See next 1/8” Cone Style. Ten (10) per pack. PART NO. 79934 VALVE FITTING, ELBOW DESIGN, COMPRESSION NUT & SLEEVE page for ordering extra Nozzles PART NO. 79936 Fits all Jet-Start Series actuator valves. 1/8” Tube x 1/8” NPT. Five (5) per pack. NYLON TUBING Five (5) feet, 1/8” O.
NOZZLES NOZZLES ARE THE HEART OF THE KATS ETHER START SYSTEM. Nozzles must be able to vaporize Fast Flash Fuel, meter the delivery of the fuel, and prevent manifold “back-flash”, without failure. All Nozzles contain a filter assembly rated at 25 microns, which prevents possible engine “blow-by” from clogging the nozzles and nylon tubing. The filter assembly helps prevents foreign contamination from installation.
INSTRUCTIONS: *1. Drain and flush radiator and block. *2. Remove correct frost plug or core plug - depending on type of engine. *3. Clean frost plug hole with a cleaning agent to remove any dirt, grease or paint. (Lubricate “O” ring with a light weight grease only, oil is not as satisfactory) before installing heater in frost plug opening. *4. Place engine heater in frost plug opening. Position of element is dependent on specific engine.
78160 78161 78162 78163 78164 79892 79893 79894 79895 1. 2. 3. 4. 5. Drain and clean cooling system. Cut and remove 1" section from the lower radiator hose at a point close to the water pump that will accept the heater. Make certain that the heater has a rise toward the water pump. Install with cap down at 5-7 oʼclock position and element pointing toward engine block. Run cord through grill and secure making sure it is clear of all moving or heated parts.
INSTRUCTIONS FOR INSTALLING AND OPERATING 1. Equipped with check valve. 2. A Model Available for all size engines. MODEL SPECIFICATIONS AND HEATERS RECOMMENDED FOR VARIOUS SIZE COOLING SYSTEMS MODELS 79401 79402 79406 79403 79405 79404 79407 79408 79409 VOLTS 120 120 240 120 240 120 240 120 240 WATTS 850 1000 1000 1500 1500 2000 2000 2000 2500 AMPS 7.00 8.3 04.16 12.5 6.25 16.6 8.3 16.6 10.4 CAPACITY Up to 18 qts. 16 - 25 qts. 16 - 25 qts. 26 - 40 qts. 26 - 40 qts. 41 - 60 qts.* 41 - 60 qts.
I N T R O D U C I N G THE NEW IMPROVED CIRCULATING TANK HEATER 79908 Made of die cast aluminum Corrosion and impact resistant Recyclable One piece molding Eliminates possibility of leaks 78340 78915 Tapered outlet design, pushes coolant more efficiently than other styles Available in 850W 1000W 1500W and 2000W 120V and 240V Thermostaticly controlled 135° - 175° 5’ HPN 105°C cord Uses versatile strap type mounting Hardware Kit 79902 SAVES FUEL COST STARTS QUICKER RUNS SMOOTHER WAR
EXTERNAL HEATER 79400 INSTRUCTIONS FOR INSTALLING AND OPERATING 1. Remove the radiator cap 2. Install the heater in a horizontal position in the hose line that returns the coolant to the water pump from the cab heater. Heater must be mounted a minimum of 4” below the outlet of the cab heater. The lower the heater is mounted, the better the circulation. It is not necessary to drain the coolant to install this heater. Hose can be clamped with two locking type pliers before cutting.
CIRCULATION TYPE ENGINE HEATER PART NUMBER WATTS HIGH LIMIT AMPS REPLACEMENT CORD 78236 750 250 F 15 N/A • Thermostatically controlled • Heavy duty cast aluminum housing • Anti back flow valve • Can be installed in any liquid-cooled gasoline diesel engine • Built in thermostat protects from burnouts and provides economical operation • Element does not come in contact with coolant, resulting in longer element life • Faster defroster action • Motor oil lasts longer during cold weather • 5/8” fitting
SPECIFICATION Heating Area Heat Output Power Req. Warranty 78345 Approx. 8 sq. in. 300 – 400° F. 110 Volt AC One-Year Limited 78344 Approx. 8 sq. in. 300 – 400° F. 110 Volt AC One-Year Limited 79880 Approx. 20 sq. in. 300 – 400° F. 110 Volt AC One-Year Limited MAGNUM 79880 300 WATTS For 1153 and 1155 magnetic heater 78331 For 1160 magnetic heater 1. Measure dipstick to see that 4" of heater is in the oil.
120 VOLTS Part No. 78037 Pre-heated interior comfort 900 Watts of power (120V) Slim, compact, lightweight design 900 Watt heat setting Thermostatically controlled Ergonomically designed to blend into any car or truck interior Easily installed, mounting bracket included 12 VOLT INTERIOR HEATERS Part No. 80013 Part No. 80014 Provides heat to interior of car, boat, campers or RVʼs 300 Watt, 12 Volt 7x7x2.
SILICONE COVERED / ACID RESISTANT / PLIABLE MODEL 79500 79501 79502 79503 79504 79505 DIMENSIONS 1" x 5" 2" x 5" 4" x 5" 4" x 5" 4" x 5" 1 5 ⁄2" x 81⁄2" VOLTS 120 120 120 120 120 120 WATTS 25 50 100 150 250 500 • • • • For Cars, Truck, Tractors Use as Oil Pan heater Use as Transmission Pan heater Easy to install NOTE: Not for use on batteries Do not cut pad Always place heater on metal reservoir before plugging in heater Application ranges may vary depending on outside temperature Do not use pads with
MODEL NO.
IMMERSION ELEMENTS THREADED MODEL # 78768 79873 78748 78693 79874 79750 78776 78696 79184 78916 78309 78313 78771 78720 79313 79100 79713 78176 78184 78413 79865 79719 WATTS 150 150 150 150 300 300 300 300 400 400 400 400 450 600 600 750 1000 1000 1500 1500 1500 1500 VOLTS 120 120 120 120 120 120 120 120 120 120 120 120 120 120 120 120 120 120 120 120 120 120 NPT THREAD SIZE 1/2" 3/4" 1" 22mm 1/2" 3/4" 1" 22mm 3/8" 1/2" 3/4" 1" 1/2" 3/4" 1" 3/4" 3/4" 1" 3/4" 1" 1" 38mm x 1.
Part Number 79898 78064 79113 78751 Length 1' 6' 10' 6' Wire 16/3 16/3 16/3 16/3 Volts 120 120 120 240 79786 79857 79671 79859 79773 5' 5' 1' 6' 8' 18/3 16/3 16/3 16/3 18/3 120 120 120 240 120 79680 79860 5' 1' 18/3 18/3 120 120 79913 78060 5' 1' 18/3 18/3 120 120 TRIPLE-CONNECTOR INDOOR/OUTDOOR 3-WIRE GROUNDED EXTENSION CORDS PART NUMBER LENGTH AMPS WATTS WEIGHT 79693 2 15 1875 1 lb.
12V Part No. 80015 24V 80016 80018 80017 Part No. 80019 12V 24V 80020 80021 80022 80023 12V Part No. 80024 24V 80025 80026 80027 80028 12V Part No. 80029 24V 80030 80031 80032 80033 Part No. 12V 80034 24V 80035 80036 80037 Part No.
HINGE COVER 79776 MALE WEATHER PROOF PLUG 78714 79999 80000 80001 80007 80009 80059 80060 80061 KITS: 79775 • (120V-15 AMP) w/35108 Cord 80002 • (120V-20 AMP) w/35109 Cord 78697 • (240V-15 AMP) w/35110 Cord 80003 • (120V-15 AMP) w/35102 Cord 80004 • (120V-15 AMP) w/35125 Cord 80058 • (120V-15 AMP) w/35121 Cord 12OV 15 AMP 12OV 20 AMP 240V 15 AMP ALL KITS INCLUDE: MOLDED RECESSED MALE RECEPTACLE CORD AND WEATHER PROOF HINGED COVER.
CARQUEST CORD LIST Carquest 78075 78077 78081 78084 78088 78091 78176 78178 78179 78180 78181 78184 78185 78186 78188 78189 78190 78194 78195 78196 78199 78200 78201 78202 78205 78213 78214 78216 78220 78222 78224 78225 78226 78260 78262 78263 78265 78266 78268 78270 78272 78273 78274 78275 78276 78278 78279 78281 78282 78283 78284 78285 78286 78287 78289 78291 78292 78293 78297 78298 78300 78301 78302 78303 78304 78305 78306 78309 78313 78314 78413 78414 78415 78416 78478 78479 78481 Kat’s Replacement Cor
TECHNICAL INFORMATION CARQUEST ENGINE HEATER - THERMOSTAT SETTINGS (RATINGS) EXTERNAL HEATERS LOWER RADIATOR HOSE HEATERS OPEN (OFF) CLOSE (ON) 175°F 135°F 79400 (IN LINE HEATER) OPEN (OFF) CLOSE (ON) 284°F 170°F MAGNETIC (78345, 78344) OPEN (OFF) CLOSE (ON) 275°F 271°F TO OBTAIN SATISFACTORY RESULTS FROM YOUR ENGINE HEATER, PLEASE READ AND FOLLOW THESE GUIDELINES. • DO NOT USE A CARQUEST ENGINE HEATER WHEN USING A 100% SOLUTION OF ANTIFREEZE—A 50/50 SOLUTION IS RECOMMENDED.
TERMS OF LIMITED WARRANTY WARRANTY: Products manufactured by Five Star Manufacturing Company are warranted for one year from date of sale to the original consumer against defects in workmanship and materials providing the installation and use of these products are in accordance with the manufacturer’s instructions and applications.
