Helton Hot Water Systems

Heat Exchanger Installation



Parts & Tools Required:
  • 1 Helton Hot Water/Shower System
  • 5/8" ID Coolant Hose (3'-6' depending on heat exchanger mounting location)
  • 4 - 3/8" Hose Clamps
  • 4 - 5/8" or 3/4" Hose Clamps*
  • Misc. Nuts & Bolts (for mounting bracket)
  • 3/8" ID High Temp Fresh Water Hose (10'+ depending on your setup)


Installation:

1. Find your heater hoses in the engine bay. You will need to find both the input of the heater, and the output of the heater (they usually come in and out of the cab at the same point). Mark the fitting locations on your heat exchanger. The 5/8" fittings are for coolant (HOT side marked with red band) and the 3/8" fittings are for freshwater (HOT side marked with red band). Mark the locations on the exchanger so you can verify proper routing with hoses installed.


(Helton heat exchanger with marked fittings)

2. Find a suitable location for the heat exchanger unit, make sure to mount it away from anything that could be damaged by heat (most things under the hood are already pretty heat resistant). Make sure that the two 5/8" hoses are going to be able to route from the heater hose connection back to the heat exchanger without kinking, etc. 
*see pictures at bottom of page for sample mounting ideas.

3. Mount the heat exchanger using the supplied bracket and small hardware that you will need to provide. Insulated clamps may be more suitable for the install. (These are available through us or your local hardware/plumbing supply store.)

4. Cut the heater hose on the HOT side of the heater core (under the hood in the most desirable spot, make sure you can easily route the hose from this spot to the heat exchanger). Remove ~1/2" of hose from the cut (to allow for the extra length of the T-Fitting) Clamp all fittings as needed.

5. Install the supplied T-Fitting into the heater hose, run a length of 5/8" coolant hose from the perpendicular fitting of the T-Fitting to the HOT COOLANT side of the heat exchanger. Clamp all fittings as needed.

6. Cut the heater hose on the COLD side of the heater core (under the hood in the most desirable spot, make sure you can easily route the hose from this spot to the heat exchanger). Remove ~1/2" of hose from the cut (to allow for the extra length of the T-Fitting) Clamp all fittings as needed.

7. Install the supplied T-Fitting into the heater hose, run a length of 5/8" coolant hose from the perpendicular fitting of the T-Fitting to the COLD COOLANT side of the heat exchanger. Clamp all fittings as needed.

8. Install the 3/8" freshwater hose as needed for your application, use one length of the 3/8" hose from the COLD FRESHWATER side of the heat exchanger to the pickup unit of the shower kit. Use another length of the 3/8" heater hose from the HOT FRESHWATER side of the heat exchanger to the shower head.


(Helton heat exchanger with freshwater and coolant lines installed)



Install Notes:

Heat Exchanger: Has 4 fittings, two 5/8" coolant fittings and two 3/8" fresh water fittings. The coolant enters the heat exchanger through the HOT COOLANT fitting (5/8" fitting marked with a red marking) and exits through the COLD COOLANT fitting (5/8" fitting marked with a blue marking). The freshwater enters the heat exchanger from the pickup unit through the COLD FRESHWATER fitting (3/8" fitting marked with a blue marking) and exits to the shower head through the HOT FRESHWATER fitting (3/8" fitting marked with a red marking).

Heat Exchanger Mounting: Although your heat exchanger will work when mounted in any position it is most efficient when mounted upright or on its side with the hot fresh water out and the engine coolant in hoses (both red collars) uppermost. 
 



Cautions:
  • First burst of water will be very hot as this water was trapped in the heat exchanger, water temp will drop to around 120° F (50°C) and then be delivered continuously for showers etc. 
  • Do not install the heat exchanger or hot water outlets inside the passenger compartment!  All components should be under the hood of the vehicle.
  • Do not drink water!  These heat exchangers are designed for showers and washing, copper oxide is poisonous and water should not be consumed. 
  • Check all hose connections!  A loose hose can cause engine damage or loss of supply water. Check hoses on a regular basis for wear and cracking.
  • We recommend using a quality automotive heater hose for your engine coolant connections.


Installed Helton Heat Exchanger Pictures


2004 Toyota Tacoma Install (Courtesy of desertdude)


99' 100 Series Landcruiser (Courtesy of kcsmithson & Ih8mud.com)


87' 60 Series Landcruiser (Courtesty of Sean Hullender & ih8mud.com)


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