HeatersTraining Guide

PROTECT YOUR VEHICLE’S ENGINE AGAINST FALLING

TEMPERATURES!Cold temperatures place extraordinary demands

on vehicle lubrication, electrical and fuel systems. Kat’s heaters offer a wide variety of effective, economical solutions to cold weather maintenance.

Three Areas to Winterize for Complete Vehicle Protection

• Engine

• Battery

• Oil & Transmission Fluid

Protecting The Engine

The frost plug, lower radiator hose heater, or circulating tank heater are designed to keep

the coolant in your engine warm. These products help stimulate warm temperatures, give quicker starts and protect your engine

from damage that can occur during cold weather starts.

The Engine Heater

Terms & Definitions

What is an Engine Heater?• An Engine Heater is an electric heater that heats the

engine of a car to ease starting in cold weather. They are connected to normal AC power overnight or before driving, via regular power outlets that are fed through a vehicle's grille. This allows easier starting in cold temperatures, by keeping the coolant warm. Heaters are also available for motor oil so that warm oil can quickly circulate and warm the engine during startup. The rapid heat circulation caused by block heaters also aids the initial vaporization of fuel in the engine; because of this effect, block heaters reduce pollution, as poor fuel vaporization causes much higher emissions.

Terms for Engine Heaters

Engine heaters are known by various names, but they all do basically the same thing, which is to heat the coolant or oil of an engine. Below are a list of common names for Engine Heaters.

• Engine Heater• Block Heater• Frost Plug Heater• Freeze Plug Heater

Types of Engine Heaters

The Basics

Types of Engine HeatersFrost Plug Heaters

•Also referred to as Freeze Plug heaters, or simply Block Heaters.•The most reliable and efficient way to pre-heat your engine.•Operates by being directly submerged into coolant and heating the block.•Application Specific Part Numbers•Requires mechanical ability to install

Selling Points: •Saves wear & tear on engine

•Cuts back on pollution as it aids in vaporization of fuel, thereby cutting back on emissions.

•The most reliable style of engine heater.

Useful Tips Regarding Frost Plug Heaters

• Most Heavy Duty Frost Plug Heaters are available with either a 120 volt or 240 volt cord set.

• Frost Plug Heaters are application specific – Meaning that the Kats Application Guide should always be used in selecting the proper heater. Each part number is designed for a specific engine type.

• If warranty issues arise from failures, we can test the product and determine the exact cause of failure.

• The most common reason for product failure is improper installation.

Types of Engine HeatersLower Radiator Hose Heater

•Easy to install/some mechanical ability required.•Thermostatically Controlled•Available in 400, 600, & 750 watt models•Available for hose diameters of one inch up to three inches.

Selling Points

•Ease of Installation•Cord permanently attached for best electrical connection.•Versatile applications.

Useful Tips Regarding Lower Radiator Heaters

• Not Recommended for any engine, American or foreign, unless specifically listed in the Application Guide. Some customers mistakenly believe that the Lower Radiator Heater can be used as long as the hose diameter matches. These are also application specific.

• Do not use on lower radiator hose which enters the engine lower than the highest point of the hose.

• Unit must be installed exactly as described in the instructions: Install with the cap down at 5-7 o’clock position and element pointing toward engine block.

Types of Engine Heaters

Circulating Tank Heater

•Available in 850W, 1000W, 1500W, and 2000W 120V and 240V.•Thermostatically controlled 135⁰ - 175⁰•Uses versatile strap type mounting.•Moderate mechanical ability required to install.

Selling Points•The die cast aluminum design makes the unit corrosion and impact resistant, as well as recyclable.•The one piece molding eliminates the possibility of leaks.•The tapered outlet design pushes coolant more effectively than other styles.•Universal Application.

Useful Tips Regarding Circulating Tank Heaters

• To ensure proper operation, the tank style heaters must be installed exactly as indicated in the instructions provided. The proper location and connection is necessary for the heaters operation, and failure to follow instructions could cause the unit to fail.

• Not recommended for any engine, American or foreign, unless specifically listed in the Application Guide.

• After installation, operate engine for 30 minutes to open engine thermostat before testing heater.

Common Failures

& Their Prevention

Engine Heater Common Failure Causes From Installation or

Operator Error and How To Prevent Them

• Engine heater plugged in while engine is running – The heating element Should Not be energized while starting the engine. The vibrations in conjunction with the added engine heat will cause the element to burn out or rupture. It is also advisable to wait a minimum of 1 minute after unplugging heater before starting engine. Additionally, if the heater is being used on a generator or other stand-by equipment an oil pressure switch for automatic cut-off may be required.

• Air not bled from system (Burned in Air Failure) - Upon installation of a new heater it is important to ensure that all air

pockets are removed from the engine before energizing the heater. Coolant levels should be checked to ensure it is properly filled. Run engine until internal thermostat opens and continue running for 20 minutes until maximum system pressure is reached, thereby eliminating air pockets. Then check for leaks before plugging the heater in for the first time. Failure to do this upon the initial installation could cause the element to burn out due to air exposure. Warning: Do not plug in heater if heating element is not immersed in coolant. If not immersed, element sheath may burst and could result in personal injury.

• Heater Failure due to lime or calcium buildup. – After installation, refill the coolant system. Check manufacturer’s instruction on mixture of antifreeze. Do not use more than 60% antifreezes. Use of non-distilled water could result in lime or calcium buildup on elements and cause premature burn out of heater. Depending upon the amount of lime or calcium in the water, this can occur in as little as a few days.

• Heater element touching engine cavity wall. – When installing your new heater, make sure to turn the element in the proper direction as indicated in the Kats Application Guide. Should any part of the heater element come into contact with a cavity wall, it will cause the element to burn out prematurely. It is advisable to remove the O-ring on the heater prior to installation, then drop the heater into place to feel for contact between the element and engine walls. Removing the o-ring should allow any contact to be felt. Once it has been determined that the element will not make contact with the cavity wall, replace the o-ring and install the heater as instructed.

• Tank style heater installed in the wrong physical location or not connected in the right locations. – To ensure proper operation, the tank style heaters must be installed exactly as indicated in the instructions provided. The proper location and connection is necessary for the heaters operation, and failure to follow instructions could cause the unit to fail.

Protecting Oil & Transmission Fluid

Oil and transmission fluids thicken and do not circulate well at cold temperatures. Silicone pads and magnetic heaters transmit heat continuously to keep oils fluid, giving you

instant lubrication when starting your engine.

Types of Oil & Transmission Heaters

Types of Engine/Oil HeatersHandi-Heat 200 watt Magnetic Heater-Model # 1155

Handi-Heat 300 watt Magnum Magnetic Heater- Model # 1160

Applications include: •Oil pan, intake manifold, battery holder or engine block.•Snow blowers, chainsaws, snowmobiles, or other small engines.•It may also be used for warming hydraulic systems or thawing frozen locks, pipes, gutters, livestock feeders, etc.

Magnum - The Magnum is an upscale version of the Handi -Heat, featuring two powerful magnets and expanded heating surface. It can be used on many of the same applications as the Handi-Heat, plus its larger size makes it ideal for use on trucks, diesels, and farm machinery.

Useful Tips Regarding Magnetic Heaters

Selling Points

• The versatility of the magnetic heaters is their biggest selling point.

• Magnetic heaters appeal to the automotive, heavy duty, and farm supply segments, as they have myriad uses.

• Magnetic heaters require no mechanical installation and are simple to use. This makes them perfect for any customer that does not have the time or ability to install a traditional engine heater.

• Magnetic heaters are convenient and reliable.

Types of Oil HeatersSilicone Pad Heaters

•Currently no CSA Approved model, however, CSA Approved models are in the design phase.•Silicone Covered, oil and acid resistant, pliable.•Use as oil pan or transmission pan heater.•Available from 25 watts to 1200 watts.

Selling Points

•Easy to install, as it requires no mechanical ability.•Universal Application.•Wide range of uses and sizes.

Useful Tips Regarding Silicone Pad Heaters

• Always place heater on metal reservoir before plugging in heater.

• Application ranges may vary depending on outside temperature.

• Do not use pads with higher than recommended wattage for specific capacities.

• Do not cut pad.

Protecting the Battery

A battery can lose 60% of its starting power when the temperature reaches 0⁰F. Cold

Engines require more power from the battery at these temperatures. These two facts make it imperative that you use a battery blanket or

pad to extend the life of your battery, and assist in your cold weather starting

requirements.

Types of Battery Heaters

Types of Battery HeatersBattery Thermal Wrap

•Vinyl covered, oil and acid resistant, pliable.•3 models to fit most battery sizes.•Fast, Easy installation.

Selling Points

•Easy Installation – Simply wraps around battery to heat and insulate.•Extends life of battery by reducing strain of cold weather starts.•Three sizes to match most battery dimensions.

Useful Tips Regarding Battery Wraps

• Fully charged batteries have a significant drop in power at colder temperatures. The battery wrap allows you to have full cranking power regardless of the cold.

• Do not operate battery heater when outside temperature is above freezing.

Types of Battery HeatersBattery Pad Heaters

•Currently no CSA Approved model, however, CSA Approved models are in the design phase.•Silicone covered, acid and oil resistant, pliable.•Fits most car and truck batteries.

Selling Points

•Easy installation. No mechanical ability required.•Nearly universal application.•Wide range of sizes in both 120 volt and 240 volt.

Useful Tips Regarding Battery Pad Heaters

• Fully charged batteries have a significant drop in power at colder temperatures. The battery wrap allows you to have full cranking power regardless of the cold.

• Do not operate battery heater when outside temperature is above freezing.

Cold Weather Starting Fluid Injection Systems

Starting Fluid Injection Systems are not engine heaters, but instead inject flash fuel (ether)

into the intake manifold, resulting in a smooth, fast, dependable cold weather start.

Starting Fluid Injection SystemsFast, Safe, Dependable – Starts Every Time

Kats 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. Kats Ether Start

products are designed to do one thing – Start Engines FAST!

Starting Fluid Injection SystemsFast, Safe, Dependable – Starts Every TimeKats Ether Start systems are truly superior heavy

duty patented products. Our components are 100% made in the USA. Customers will find Kats Ether Start systems are unbeatable in

pricing, quality, and performance anywhere. Kats manufacturing quality control procedures

assure you the very best anytime you install and operate a Kats system.

Ether Start Systems•Ether start systems burn pollution free and are environmentally helpful by reducing emissions.•Available for a variety of application types and equipment sizes.•Available in the Automatic Electric 33200 series, Push-Button Electric 33100 series, and the Pull-Cable Manual Control 33180 series.

Selling Points

•Environmentally Friendly•Kats is the only manufacturer that offers a 90% High Grade Ethyl Ether solution – That’s 20-25% more than our competition.•High quality, hand-made product.

Useful Tips Regarding Ether Start Systems

• All systems available to operate on 12 or 24 volt requirements.

• All systems available with an 18 oz. or 21 oz. ether fuel cylinder.

• The Automatic and Push-Button series will only operate at 50⁰F or below, while the Pull-Cable series can be engaged any time the operator determines that a “hard starting” situation exists.

Summary

Five Star Mfg./Kats produces top quality products that are designed to assist the customer in all facets of

winterizing their vehicles. We build quality products to assist in almost any cold weather application for most vehicles. This presentation is a primer and is

not meant to cover the entire scope of our products and their myriad applications. Feel free to contact us at 1-888-872-7278 for in depth questions or special

application information.

Quality Policy Statement

Five Star Manufacturing believes that quality excellence is a basic requirement in the design, manufacture, and delivery of our

products and services. Our quality policy is Total Customer Satisfaction in the delivery

of products and services to consistently meet evolving customer expectations. We

shall continuously pursue quality improvement programs that enable each

employee to do his or her job right the first time and each time.