IMC-500

Technical Information & Heater Installation InstructionsOPERATING PRINCIPLEThe Kim Hotstart Engine Heater operates on the principle of a thermosiphon. As the temperature of the coolant in the heatertank increases, it’s density decreases causing it to rise through the outlet of the tank to the engine. The coolant leaving theheater tank is replaced with coolant drawn from the engine and the cycle is repeated. A flow-through thermostat is availablefor the inlet of the engine heater that keeps coolant within the preset temperature range.CAUTIONPrior to heater installation, check the cooling system. Poor coolant conditionswill interfere with proper function of the heater and can also cause elementfailure. If there is sediment or foreign matter present or the coolant does notmeet the engine manufacturer’s specifications, the system should be drained,cleaned, flushed and refilled with a 50/50 mixture of low silicate antifreeze,deionized water, and low silicate supplemental coolant additives. Do not exceeda concentration of more than 60% antifreeze, as element failure may result. Acooling system containing anti-leak additives can cause premature elementfailure.MOUNTINGMount the tank heater in a horizontal position with the outlet neck pointed up.The heater can also be mounted vertically with the inlet neck as the low point(see figure 1).Bolt the heater to the truck frame or skid frame on a generator package withthe mounting straps provided. See Figure 2.The heater must be mounted belowthe lowest level of the engine water jacket to ensure a good gravity flow ofcoolant to the heater.Outlet NeckOutlet NeckInletInletVERTICAL MOUNTHORIZONTAL MOUNTFIGURE 1CAUTIONYESDO NOT mount the heater to the engine. Engine vibration can damage theheater and void the warranty.Connect the heater intake to the lowest accessible point of the water jacket. If aconnection point is unavailable in the water jacket area, connect heater intakeline to lower radiator hose.This hose should run down to heater intake.Connect heater outlet to the highest accessible point in the engine’s waterjacket area at the furthest point from the engine’s thermostat.The heater outletmust be connected at a higher point on the engine than the intake. See Figure3.NOLowest level of water jacketFIGURE 2YESNOCAUTIONDO NOT route outlet hose above engine block connection, or loop or kink hoses.This will cause air locks in the hose and block circulation of the coolant by theheater. See Figure 3.To eliminate air locks in the heater and hoses, refill the engine with the heateroutlet line disconnected at the engine until outlet line is full of coolant. SeeFigure 4-1.Then connect the outlet line to the engine and finish filling theengine. See Figure 4-2.Before energizing heater, all air must be bled out of the system by running theengine. If not, air could be trapped in the block causing the heater to fail.FIGURE 3YES1NO2NOCAUTIONThe bi-directional ball check valve located in the inlet of the heater allows areduced amount of coolant to reverse flow through the heater when the engineis running.This will maintain a full coolant level in the tank at all times toprotect the element from overheating.This is a safety device only. Kim Hotstartrecommends NOT running the engine with the engine heater energized.On standby and automatic start engines, heaters should be de-energized whenengine starts.This requires an oil pressure switch or other automatic cut-off.These systems are often operated at voltages above the 277 Volt rating of theKim Hotstart thermostat and are also often 3 Phase. All heaters above 277 Voltshould be used in conjunction with a contactor and control transformer. Allthree phase heaters must be used with a contactor. See pages 37, 38, and 39.40Coolant FlowFIGURE 4Note: It is recommended for “V” engines larger than eight cylinders or over 1000C.I.D. that 2 heaters of equal wattage be used. One heater installed on each bankof the “V”.Example:To adequately heat a 1000 cubic inch “V” engine for ambient temperatureabove -20 F use (2) 2000 watt heaters — total 4000 watts.For the most efficient heating of this size engine and electrical savings, see theforced circulatiing heating system on pages 16 & 17.

Section 5Battery PadsBattery WrapsSilicone Hot Pads41

A fully charged battery has only 40%cranking power at 0 F when comparedto 100% cranking power at 80 F.BatteryHeating PadsBattery heater not recommended fornickel cadmium batteries.When batteries are placed in aninsulated battery box, a thermostat isrecommended to sense battery boxtemperature to prevent overheatingthe battery.Special Pads for Multiple BatteriesStandard Pad for Single Battery9.00REF TYPB16-3 HPNStyle A9.00REF TYPBStyle BBStyle CAA16-3 HPNA6" HPN100Typical Connection - 2 Batterieson Each Side of Vehicle80Percent of Battery Cranking PowerKB7515-SKB7515-DKB7515-DRight Side Battery BoxKB7515-DLeft Side Battery BoxGroundBEC-6BY-T68BPC-61NominalModel Volts Watts Amps Dimensions Batt. StyleNumberSizeABKB5015120KB5015-S 120KB5015-D 1205050508 1/48 1/48 1/4.42.42.421313134D4D4DABC604020KB7515120KB7515-S 120KB7515-D 120757575.63.63.6310 1/2 19 1/210 1/2 19 1/210 1/2 19 1/28D8D8DABCKB7523240KB7523-S 240KB7523-D 240757575.31.31.3110 1/2 19 1/210 1/2 19 1/210 1/2 19 1/28D8D8DABC0-200 20 40 60 80Ambient Temperature, FAccessories For Multiple Battery Heating2 FT4 FT6 FT8 FT3 FT6 FT15.375"15.375"CORD, 16-3 HPN16-3 HPN15.375"EXTENSION CORDS42POWER SUPPLY CORDSTHERMOSTAT & “Y” CORD ’6’6’120240120240ModelBY-T68Temperature ControlOnOff60 F80 F

Prolong the life of your battery with Kim Hotstart thermal battery wraps with or withoutthermostat. Durable, fire-retardant vinyl cover that resists oils and acids. All standard battery pads and battery wraps come with 6’ grounded cord and plug. Fast, easy installation.BatteryThermalWrap Boosts battery cranking power as much as 75%.BATTERY THERMAL WRAP — NO THERMOSTATModel lly controlled battery thermal wraps provide optimum heating regardless ofambient temperature. At 80 F, the battery will achieve maximum cold cranking amps. Battery is constantly maintained at 80 F. Provides greater heat rise than plates or pads. Thermostat will eliminate battery damage caused by overheating and acid spill.Thermostat range: 65 F - 80 FBATTERY THERMAL WRAP — WITH THERMOSTATModel ”56”43

SiliconeHot PadsFlexible, Versatile and Easy to Install.Kim Hotstart adhesive Hot Pad Heaters are ideal for oil pans, hydraulic reservoirs, engineblocks, hydraulic cylinders and diesel fuel tanks. Easy peel and stick application Etched foil heating element for optimal heat transfer and long life Durable silicone/fiberglass cover resists abrasion Assembled with a standard 6 ft. HPN cord and plug (240V without plug)Not for use on batteriesModel NumberDimensionsVoltsWattsAF10015AF100244” x 5”120240100100AF15015AF150244” x 5”120240150150AF25015AF250245” x 6”120240250250AF40015AF400246” x 8”120240400400ApplicationGuidline100 Watt150 Watt250 Watt400 WattEngine oil pan2 to 5 quarts5 to 8 quarts2 to 5 gallons5 to 8 gallonsDiesel Tank5 to 7 gallons7 to 10 gallons10 to 20 gallons20 to 30 gallonsHydraulic Tank1 to 5 gallons5 to 10 gallons10 to 20 gallons20 to 30 gallonsWater Tankup to 2 gallons2 to 4 gallons4 to 7 gallons7 to 10 gallonsCAUTION: Do not use pads with higher than recommended wattage for specific oil capacities.44

Section 6In-block HeatersHeater InstallationGuideIn-line HeaterDirect ImmersionCordsThermocordsFlush Mount Kits45

In-BlockDirect Immersion HeatersEngine ModelPart Number Part Number120 Volts240 VoltsNote: In-block heaters are complete with 2-wire w/ground 6 footHPN cord and plug. For cord replacements or “Y” thermocordenergy saver, please reference page 56.WattsProduct ImageApplication InformationHeat ShieldRequiredOil HeaterThread Size*Allis Chalmers670T & I685T & I6138LT,T & I25000 (844 CID)AC-101CATV-151AC-102CATV-15210001500Replaces 1” thread-in plug on the oil cooler atrear of the engine on the right side. Note thatnot all of the engines have this opening.Case/IH – AgriculturalALL 4 CYL 390ALL 6 CYL B-152FP75010001500Inserts in any of the freeze plugs right side ofengine22mmALL 6 CYL 830CUC-151FPCUC-152FP1500Inserts in the freeze plug right rear of 250Replaces the 1” threaded plugin the oil cooler bonnetC-9 Non ACERTC-15 Non ACERTC-16 Non ACERTCATV-151CATV-1521500C-9 Only: Mount in rear face of blockC-15, C-16: Mount in rear oil cooler bonnetfrom the back endC7 500Replace 44mm frost plug on right hand sideof engine just below the turbo charger.C7 ACERT rear portTL101-000TL102-000C9 ACERTCATV-151CATV-1521500C11 ACERTC13 ACERTTF151-008TF152-0081500Replace any of the 1-5/16” plugs in rear of oil Check Exhaustcooler on the right hand side of the engineRoutingC15 ACERTw/o breaksaverTF151-009TF152-0091500Replace 1-3/16” plug in rear of the oil cooleron the right hand side of the engineC15 ACERTwith breaksaverTF151-008TF152-0081500Replace 1-5/16” plug in the oil cooler on therigh handside of engineC9 2007 ACERTC13 2007 ACERTC15 2007 ACERTTF151-012TF152-0121500Replace 1-3/16” plug in the rear of the oilcooler on the right hand side of the engine1674CATB-151CATB-1521500Replaces the 1-1/2” thread-in plugon the right side of the engine1693 & D343CATC-151CATC-1521500Replaces water jacket access plate on the leftside of the engine1693T & 1693TACATC-151-SCATC-152-S1500Replaces water jacket access plate on the leftside of the engine3013 1.5L3014 2.0LFP531-003FP532-003530Replaces 40mm core plug on the front, leftside of the engineYES1” NPTYESReplace 1-1/16” plug in the rear of the blockReplace 1” NPT plug in the right rear of theengine block* If supplemental oil heating is desired, this column gives the correct thread size in oil pan. See NOTE on page 54.461” NPT1 5/16”STOR

In-BlockDirect Immersion HeatersEngine ModelPart Number Part Number120 Volts240 VoltsNote: In-block heaters are complete with 2-wire w/ground 6 footHPN cord and plug. For cord replacements or “Y” thermocordenergy saver, please reference page 56.WattsProduct ImageApplication InformationHeat ShieldRequiredOil HeaterThread Size*YES11/16”X12Caterpillar — Continued3024 2.22LFP531-003FP532-003530Replaces 40mm core plug on the front, leftside of the engine3034 2.95LFP531-001FP532-001530Replaces 50mm core plug located at back ofhead3044 3.3LPF531-001PF532-001530Mounts in “football shaped” opening on theright of the engine3046 5.0LPF531-000PF532-000530Replaces 35mm core plug located at rear ofengine, left side3054 3.99L3054B unts in the 1-1/4” freeze plug opening onthe left side of the engine3054CPER-751FPPER-752FP750Mounts in 1-1/4” freeze plug at left rear ofengine3056 6.0LPER-151FPPER-152FP1500Mounts in the 1-1/2” freeze plug on the rightside of the 10001500Replaces the core plug on the right side ofthe engine just below the turbocharger3176 10.3Lthrough 52-001100012501500Replaces the 3/4” plug on the right side ofthe engine just below the head.3176 10.3L1996 and laterTF121-000TF122-0001250Replaces the 1” threaded plug in the oilcooler bonnetYES11/16”X123196 12.0LTF121-000TF122-0001250Replaces 1”threaded plug in oil cooler bonnetYES11/16”X123204all 1100 ces the core plug on the right side of theengine just below the turbocharger3208 — 2 heaterswith a single cordCATX-2-751-YCATX-2-752-Y1500totalUse on industrial engines when clearaccess is available.Replaces any core plug - one on each sideof the 02INJD3/4-152INJD1-152IN1000100015001500Replaces any of the 3/4” or 1” plugs on thewater transfer casting (right front of theengine). 3/4” use JD3/4 — 1” use 2023TF152-001100012501500Replaces the 3/4” plug on the left side ofthe engine3406C/E 14.6LAC-101CATV-151AC-102CATV-15210001500Replaces 1”thread-in plug in the rear of the oilcooler bonnet on the right side of the engine1” NPT22mm1” NPT* If supplemental oil heating is desired, this column gives the correct thread size in oil pan. See NOTE on page 54.47

In-BlockDirect Immersion HeatersEngine ModelPart Number Part Number120 Volts240 VoltsNote: In-block heaters are complete with 2-wire w/ground 6 footHPN cord and plug. For cord replacements or “Y” thermocordenergy saver, please reference page 56.WattsProduct ImageApplication InformationHeat ShieldRequiredOil HeaterThread Size*Caterpillar — Continued3406 & 3408except 1998ADEM 2AC-101CATV-151AC-102CATV-15210001500Replaces 1”thread-in plug in the rear of the oilcooler bonnet on the right side of the engine3406E1998 ADEM 2engines onlyTF151-002TF152-0021500Replaces the 1” threaded plug that pointsdownward on the top of the rear of the oilcooler bonnet3406EADEM 3 and ADEM2000 s 1” thread-in plug in the rear of theoil cooler bonnet on the right side of theengine1” NPT3456 15.8LAC-101CATV-151AC-102CATV-15210001500Replaces 1” thread-in plug in the rear of theoil cooler bonnet on the right side of theengine1” NPT1” NPTYES1” NPTChevrolet/GMC (Small Truck)5.7L V8 (350 CID)FC601-501NONE6.2L V8 Diesel6.5L V8 DieselMounts in the freeze plug in the engine’sblockNo replacement cord available600FC601-PY2Cummins6 Cylinder Engines:H,NT,NH,N Family743 CID,855 CID,927 CID,“N14”1.Cummins engines are often referred to by their horsepower rating “i.e.350 Cummins”2.Cummins engines are often referred to as Big Cam,Big Cam2,3,4,full flow cooling,etc.All refer to engines of 855 CID Size – listed belowGroup IFlat plate designFlat plate design whenthe 1/2”NPT openingis usedCUN-151BCUN-152B15001” NPT6 bolt flat plate on the right side of theengine. May use either the forward or rearopening depending on clearance.CUN-151BHCUN-152BH15001” NPTGroup IIWhen an external oil cooler is used.When connectionis 1 1/2”rubber hose CNT-151B-90Engines produced Aug.1975 thru June 1982Uses an “O”ring forthe 1 1/4”water tubeconnectionEngines producedprior to August ‘75CNT-151BNote: When a 4 bolt flat plate element design is encountered,remove the next two bolts on the casting,remove the whole casting,and replace the casting and element with either CNT-151B/CNT-152B OR CNT151B90/CNT152B90CNT-152B-9015006 bolt, flat plate design with an elbow thatwill rotate 360 degrees to connect with anyhose or casting1” NPTCNT-152B15006 bolt, flat plate design with an elbow thatwill rotate 360 degrees to connect with anyhose or casting1” NPT* If supplemental oil heating is desired, this column gives the correct thread size in oil pan. See NOTE on page 54.48

In-BlockDirect Immersion HeatersEngine ModelPart Number Part Number120 Volts240 VoltsNote: In-block heaters are complete with 2-wire w/ground 6 footHPN cord and plug. For cord replacements or “Y” thermocordenergy saver, please reference page 56.WattsProduct ImageApplication InformationHeat ShieldRequiredOil HeaterThread Size*Cummins — ContinuedGroup IIIFor industrial engineswith hole pattern CUN-151BREVreversedCUN-152BREV1500Six bolt flat plate on the right side of theblock1” NPTPF152-0021500Six bolt flat plate on the right side of theblock1” NPTGroup IV1998 and laterN14 IndustrialPF151-002Additional Cummins Engine ModelsCummins A4 cyl & 6 cylCUA-101FCUA-102F1000Inserts in any of the freeze plugs on rightside of engine. Element points down.ISC/QSC 8.3LISL/QSL 9.0LDD8L-101DD8L-10210003/4” NPT threaded plug in theright rear side of engine22mmL10, M11ISMCUL-151CUL-1521500Inserts in the forward opening of the heatercasting on the right rear of block1” NPTQSB 3.9L, 5.9LISB 5.9TF751-002TF752-0027503/4” NPT threaded plug in the frontof the oil cooler casting22mmISM/QSM 11.0LFlat Plate DesignPF151-003PF152-0031500Right rear. Replaces plate.1” NPTQSX, ISXSignature 600PF151-004PF152-0041500Mounts in the “football shaped” plate on theright side of the block27mm4BT erts in any of the freeze plugsright side of engineCheck ExhaustRouting22mm6BT UB-152FP75010001500Inserts in any of the freeze plugsright side of engineCheck ExhaustRouting22mm6CT 8.3LCUC-151FPCUC-152FP1500Inserts in the freeze plugright rear of the block22mmDetroit DieselSERIES 104 cylinderPhaser Mounts in the 1-1/4” freeze plug opening oneither side of the engineSERIES 106 cylinderPhaser enginesPER-151FPPER-152FP1500Mounts in the 1-1/2” freeze plug on the rightside of the engineSERIES 30DD8L-101DD8L-1021000Mounts in the 3/4” NPT opening in the block* If supplemental oil heating is desired, this column gives the correct thread size in oil pan. See NOTE on page 54.49

In-BlockDirect Immersion HeatersEngine ModelPart Number Part Number120 Volts240 VoltsNote: In-block heaters are complete with 2-wire w/ground 6 footHPN cord and plug. For cord replacements or “Y” thermocordenergy saver, please reference page 56.WattsProduct ImageApplication InformationHeat ShieldRequiredOil HeaterThread Size*Detroit Diesel – continuedSERIES 40all 2FR152-00175012501500Mounts in the frost plug opening on the leftside of the engineSERIES 50SERIES 60AC-101CATV-151AC-102CATV-15210001500Mounts in the 1” NPT opening in either water yes on 1991 andpick up pipe (up to 1991) or in the 1” NPTlateropening on the oil cooler housing after 1991SERIES 55PF151-000PF152-0001500Mounts in the triangle plate on the sideof the block3-53, 4-53, 3-71,4-71 with watercooled air compressorDD-751-SDD-752-S750Mounts in

Kim Hotstart was established in 1942 with the original patent for engine coolant heating. We manufacture engine heating equipment and accessories that provide easy starts, reduced fuel consumption, reduced wear, and reduced emissions. As a world wide distributor of electric heating equipment for gasoline and diesel engines, Kim Hotstart has the .