Catalog Hotstart IMC-600

IMC-600

ProductCatalog

Engine Heaters

Oil Heaters

Controls

Accessories

• Reduces engine wear.

• Immediate flow of warm oil to criticalengine parts.

• Stops destructive condensation and theforming of sludge in oil.

• Warm oil allows easier starts andprolongs battery life.

• Models designed for heatingtransmission fluid, hydraulic oil anddiesel fuel.

• Low watt density elements assure safeheating of oils and will not char or coke.

• Thermostat control available andrecommended for all models.

• Innovative threadless design V-clampstyle mounting adapter available.

Easy Starts…• Saves warm-up time

• Saves fuel

• Prolongs battery life

• Provides immediate defrosting

Reduces Engine Wear…• 90% of engine wear is due to low water

jacket temperature

• Stops destructive condensation

• Extends time between overhauls

Protects the Environment…• Eliminates “White Smoke” upon start-up

• Reduces idle time

• Engine is ready for clean full poweroperation

• Reduces noise pollution

• No high speed idle

2

HOTSTART...YOUR ENGINE HEATINGEXPERTS!

HOTSTART was established in1942 with the original patentfor engine coolant heating. Wedesign and manufacture engineheating equipment andaccessories that provide easystarts, reduced fuelconsumption, reduced wear, andreduced emissions. As a worldwide distributor of electricheating equipment for gasolineand diesel engines, HOTSTARThas the experience and expertiseto solve your engine heatingproblems.

Contact us today.

Tank Style Coolant Heaters That Meet Heating RequirementsFor a Wide Range of Engine Sizes and Applications.

Industrial Lube Oil Heaters and Process Oil Heaters. MultipleSizes Available for Every Oil Heating Need.

• Constant circulation of coolant throughthe engine achieves even heatdistribution.

• One-piece, heavy-duty, pressure die-castaluminum tank with a bolt-on flangeelement assembly.

• All parts replaceable — easy to service.

• Most models classified weathertight.

• Many models available for Class I, GroupD (Hazardous Locations) applications.

• Various voltages and phases available.

• CSA C/US and UL C/US approved.

HOTSTART Engine Heaters

3

All Direct Immersion Block Heaters Carry CSA C/USapproval and are CE compliant.

Battery Warming Pads and Thermal Wraps Improve CrankingPower in the Coldest Conditions.

Silicone Hot Pads are Flexible and Easy to Install.

Thermostat Controls, Complete Control Systems and OtherAccessories Ensure Proper and Efficient Performance of KimHotstart Heaters.

• Ideal for oil pans, hydraulic reservoirs,engine blocks and hydraulic cylinders.

• Durable silicone/fiberglass cover resistsabrasion.

• General purpose, weathertight andexplosion proof thermostats availablefor all engine heating, oil heating andbattery heating applications.

• Fixed temperature and adjustable.

• Oil pressure switches for automatic cut-off of heaters on engine start-up.

• Complete control systems for 3 phaseand high voltage engine preheatersfactory assembled in electrical boxes forease of installation.

• Long life Incoloy elements withstand highertemperatures to reduce element failure.

• Reduced heat in terminal connection area.

• Resists scale build-up on element surface.

• Tensile strength of Incoloy is three timesthat of copper, making it much lesssusceptible to engine and road vibration.

• Available in 120 volt and 240 volt.

• The 6ft. power cord and plug carries alifetime warranty; standard equipmenton all in-block heaters.

• Optional thermostat control and “Y”harness available for all Kim-Glo heaters.

• Flexible SBR rubber pads are designedfor installation under the battery to heatfrom the bottom up.

• Blanket-style heaters and pad heatersare impervious to battery acid and oil.

• Pad models for multiple batteryapplications available with accessorycords and thermostat assembly.

• Blanket-style warmers provide greaterheat rise than plates or pads.

• Engineered to maintain batteries at80°F/27°c to ensure full cranking power.

4

Pages 6 -18 Section 1

Tank Style Coolant HeatersWeathertight DesignOriginal Equip. Replacement HeatersCirculating System with Pump

Pages 20 - 24 Section 2

Tank Style Coolant HeatersClass 1, Group D for Hazardous Locations


Battery Warming Pads and AccessoriesBlanket Style Battery WarmersSilicone Hot Pads


Industrial Lube Oil Heaters Lube Oil Heaters with ThermostatProcess Immersion Heaters with Fixed or Adjustable Thermostat


Temperature ControlsPressure SwitchMagnetic ContactorsJunction BoxesComplete Control Systems


In-block Direct Immersion HeatersIn-line Coolant HeaterElectrical Cords for In-block HeatersThermocordsFlush Mount Kits and Accessories

TABLE OFCONTENTS

Heater InstallationGuides:

Tank-style – Page 40In-block – Page 56

How to Specify anEngine Heater andConversion Charts

– Page 58

Industrial Circulating Systems

– Page 16, 17, 59

Custom Products

Call for information on:Battery ChargersWiring Harnesses

Air Intake HeatersDiesel Driven Heating Systems

Other Specialty Products

5

Section 1

Industrial Tank StyleCoolant Heaters

6

HOTSTART TPS tank heaters are constructed from a durable, high-impact plastic. Every heater is assembled with abuilt-in thermostat and 4–foot power cord.

Small Tank

HeatersTPS Model

Single Phase

500-2000 Watts

120V & 240V

HOTSTART Engine Heating. P.O. Box 11245 Spokane, WA 99211-0245

AmbientAbove-20° F

AmbientBelow-20° F

Model Number Volts Watts Phase AmpsThermostat Range

On Off

150 Cubic Inch

or Less

150 Cubic Inch

or Less

TPS051GT8-000TPS051GT10-000TPS051GT12-000TPS052GT8-000TPS052GT10-000TPS052GT12-000

120120120240240240

500500500500500500

111111

4.24.24.22.12.12.1

80°F 100°F100°F 120°F120°F 140°F

80°F 100°F100°F 120°F120°F 140°F

350Cubic Inch

or Less

200Cubic Inch

or Less


120120120240240240

100010001000100010001000

111111

8.48.48.44.24.24.2

80°F 100°F100°F 120°F120°F 140°F

80°F 100°F100°F 120°F120°F 140°F

350 — 500Cubic Inch

or Less


or Less


120120120240240240

150015001500150015001500

111111

12.512.512.5

6.36.36.3

80°F 100°F100°F 120°F120°F 140°F

80°F 100°F100°F 120°F120°F 140°F


or Less


or Less


120120120240240240

180018001800200020002000

111111

151515

8.38.38.3

80°F 100°F100°F 120°F120°F 140°F

80°F 100°F100°F 120°F120°F 140°F

ModelNumber Volts Watts

ThermostatRange

On Off

Replaceable Parts

T-Stat Element Tank Box PowerCord

ElementO-ring


120120120240240240

500500500500500500

80°F 100°F100°F 120°F120°F 140°F

80°F 100°F100°F 120°F120°F 140°F

LSU-8LSU-10LSU-12LSU-8LSU-10LSU-12

REPS051T8REPS051T10REPS051T12REPS052T8REPS052T10REPS052T12

TPS-TTPS-TTPS-TTPS-TTPS-TTPS-T

CPS-1CPS-1CPS-1CPS-1CPS-1CPS-1

11P48UU11P48UU11P48UU21P48UU21P48UU21P48UU

TPS-BORTPS-BORTPS-BORTPS-BORTPS-BORTPS-BOR


120120120240240240

100010001000100010001000

80°F 100°F100°F 120°F120°F 140°F

80°F 100°F100°F 120°F120°F 140°F








120120120240240240

150015001500150015001500

80°F 100°F100°F 120°F120°F 140°F

80°F 100°F100°F 120°F120°F 140°F







TPS181GT8-000TPS181GT10-000TPS181GT12-000

120120120

180018001800

80°F 100°F100°F 120°F120°F 140°F

LSU-8LSU-10LSU-12

REPS181T8REPS181T10REPS181T12

TPS-TTPS-TTPS-T

CPS-1CPS-1CPS-1

12P48UU12P48UU12P48UU

TPS-BORTPS-BORTPS-BOR

TPS202GT8-000TPS202GT10-000TPS202GT12-000

240240240

200020002000

80°F 100°F100°F 120°F120°F 140°F

LSU-8LSU-10LSU-12

REPS202T8REPS202T10REPS202T12

TPS-TTPS-TTPS-T

CPS-1CPS-1CPS-1

21P48UU21P48UU21P48UU

TPS-BORTPS-BORTPS-BOR

ReplacementParts

For TPS Model heaters

ReplacementCord

ReplacementBox

ReplacementTank

ReplacementThermostat

ElementO-Ring

ReplacementElement

In-LineAdjustableThermostat

RemoteThread-in

FixedTemperatureThermostat

6.7

7.9

OUTLET HOSEBARB .625 I.D.

INLETHOSEBARB

.625 I.D.Thermostat

Well

Power Y-cord

Adj. T-statAssembly

4.25

4.6

1.5.25 (4X) HolesFor Mounting

Brackets

7Customer Support: (509) 536-8660 Toll-Free FAX: (800) 224-5550 www.hotstart.com

ADJUSTABLE 90-130°F(On differential – 20° F)

In-line thermostat options:

AmbientAbove-20° F

AmbientBelow-20° F

Model Number Volts Watts Phase AmpsThermostat Range

On Off

150 Cubic Inch

or Less

150 Cubic Inch

or Less

TPS051GT12-001*TPS051GT12-A00TPS052GT12-001*TPS052GT12-A00

120120240240

500500500500

1111

4.24.22.12.1

100°F 120°FADJUSTABLE


350Cubic Inch

or Less

200Cubic Inch

or Less


120120240240

1000100010001000

1111

8.48.44.24.2




or Less


or Less


120120240240

1500150015001500

1111

12.512.5

6.36.3




or Less


or Less


120120240240

1800180020002000

1111

1515

8.38.3



* Remote thread-in fixed temperature thermostat

Small TankHeatersTPS Model w/in-lineadjustable and remotethread-in fixed thermostat

Single Phase

500-2000 Watts

120V & 240V

Common ReplacementParts For ALL TPS ModelHeaters:

- Tank

- Box

- Element O-ring

See table on p. 6


ThermostatRange

On Off

Replaceable Parts

SensingUnit

Element PowerY-cord

ThermostatWell


120120240240

500500500500



LSU-10RSU90-130LSU-10RSU90-130

REPS051T12REPS051T12REPS052T12REPS052T12

TPS-YC1#

TPS-YC2#

TW2374-1#

TW2374-1#


120120240240

1000100010001000





TPS-YC1#

TPS-YC2#

TW2374-1#

TW2374-1#


120120240240

1500150015001500





TPS-YC1#

TPS-YC2#

TW2374-1#

TW2374-1#


120120240240

1800180020002000





12P16H54S54X10UU#

TPS-YC2#

TW2374-1#

TW2374-1#

* Remote thread-in fixed temperature thermostat # Call Factory

ReplacementPartsFor TPS Model heatersw/in-line adjustable andremote thread-in fixedthermostat

8 HOTSTART Engine Heating P.O. Box 11245 Spokane Valley, WA 99211-0245

IndustrialTank

Heaters(Conduit Connection)

1500 - 5000 watt

Weathertight

Single Phase

CB Model withoutthermostat.

CB Model assembled withthermostat.

*Figure Number refers to technical drawings of heaters located on page 14.

CL Model assembled with thermostat.

CL Model withoutthermostat.

AmbientAbove-20° F

AmbientBelow-20° F

Model Numberwithout

Thermostat

Model Number with Thermostat

(see chart 1)Volts Watts Phase Amps Fig.*

No.


or Less


or Less

CB115100-000CB115800-000CB115200-000CB115700-000CB115300-000CB115400-000

CB1151XX-000CB1158XX-000CB1152XX-000CB1157XX-000CB1153XX-000CB1154XX-000

120208240277380480

150015001500150015001500

111111

12.57.26.35.43.93.1

111111


or Less


or Less

CB120100-000CB120800-000CB120200-000CB120300-000CB120400-000

CB1201XX-000CB1208XX-000CB1202XX-000CB1203XX-000CB1204XX-000

120208240380480

20002000200020002000

11111

16.79.68.35.34.2

11111


or Less


or Less

CB125100-000CB125800-000CB125200-000CB125700-000CB125300-000CB125400-000

CB1251XX-000CB1258XX-000CB1252XX-000CB1257XX-000CB1253XX-000CB1254XX-000

120208240277380480

250025002500250025002500

111111

20.812.010.4

9.06.65.2

111111


or Less


or Less

CL130100-100CL130800-100CL130200-100CL130700-100CL130300-100CL130400-100

CL1301XX-100CL1308XX-100CL1302XX-100CL1307XX-100CL1303XX-100CL1304XX-100

120208240277380480

300030003000300030003000

111111

25.014.412.510.8

7.96.3

333333


or Less


or Less

CL140800-100CL140200-100CL140700-100CL140300-100CL140400-100

CL1408XX-100CL1402XX-100CL1407XX-100CL1403XX-100CL1404XX-100

208240277380480

40004000400040004000

11111

19.216.714.410.5

8.3

33333


or Less


or Less

CL150800-100CL150200-100CL150700-100CL150300-100CL150400-100

CL1508XX-100CL1502XX-100CL1507XX-100CL1503XX-100CL1504XX-100

208240277380480

50005000500050005000

11111

24.020.818.113.210.4

33333

INSTALLATION TIPSIf you require a 1” NPT female thread on the

thermostat intake, a coupler is available. Also, for theuse of 3/4” or 1” ID heater hose, hose barb adapters

are available. See below.

Part Number Description

HB-11” NPT to 1” hose barb adapter.Installs in 1” NPT female inlet oroutlet of the heater.

HB-3/41” NPT to 3/4” hose barb adapter.Installs in 1” NPT female inlet oroutlet of the heater.

HB-C1” NPT x 1” NPT aluminum coupler.Installs on 1” NPT inlet to T-Stat andallows the addition of HB-1 or HB-3/4.

HB-K3/4 Kit contains (2) HB-3/4 and (1) HB-C

HB-K1 Kit contains (2) HB-1 and (1) HB-C

CHART 1

HEATERS WITH THERMOSTATS

To specify temperature range of thermostat, insertnumerical code from chart in place of the XX in modelnumber.

Example:

Desired Temperature Range 100° - 120°FCatalog Number: Model CB1151XX-000Order as: Model CB115110-000

All heatersover 277vand all 3Øunits must

use a controlbox

See ControlSystemspage 38

TEMPERATURE RANGE NUMERICALCODEON OFF

60°F80°F100°F120°F140°F

80°F100°F120°F140°F160°F

0608101214

Adjustable 90° - 130°F A3


Model Number Volts Watts Replaceable Parts

Element Tank Box ElementO-ring

MountingKit

CheckValve

CB115100-000CB115800-000CB115200-000CB115700-000CB115300-000CB115400-000

120208240277380480

150015001500150015001500

RECB1151RECB1158RECB1152RECB1157RECB1153RECB1154

RTBRTBRTBRTBRTBRTB

RTBCBRTBCBRTBCBRTBCBRTBCBRTBCB

TMM-ORTMM-ORTMM-ORTMM-ORTMM-ORTMM-OR

FK2FK2FK2FK2FK2FK2

RV-MRV-MRV-MRV-MRV-MRV-M

CB120100-000CB120800-000CB120200-000CB120300-000CB120400-000

120208240380480

20002000200020002000

RECB1201RECB1208RECB1202RECB1203RECB1204

RTBRTBRTBRTBRTB

RTBCBRTBCBRTBCBRTBCBRTBCB

TMM-ORTMM-ORTMM-ORTMM-ORTMM-OR

FK2FK2FK2FK2FK2

RV-MRV-MRV-MRV-MRV-M

CB125100-000CB125800-000CB125200-000CB125700-000CB125300-000CB125400-000

120208240277380480

250025002500250025002500

RECB1251RECB1258RECB1252RECB1257RECB1253RECB1254

RTBRTBRTBRTBRTBRTB

RTBCBRTBCBRTBCBRTBCBRTBCBRTBCB

TMM-ORTMM-ORTMM-ORTMM-ORTMM-ORTMM-OR

FK2FK2FK2FK2FK2FK2


CL130100-100CL130800-100CL130200-100CL130700-100CL130300-100CL130400-100

120208240277380480

300030003000300030003000

RECL1301-100RECL1308-100RECL1302-100RECL1307-100RECL1303-100RECL1304-100

RTLRTLRTLRTLRTLRTL

RTBCL-100RTBCL-100RTBCL-100RTBCL-100RTBCL-100RTBCL-100

TML-ORTML-ORTML-ORTML-ORTML-ORTML-OR

FK6FK6FK6FK6FK6FK6


CL140800-100CL140200-100CL140700-100CL140300-100CL140400-100

208240277380480

40004000400040004000

RECL1408-100RECL1402-100RECL1407-100RECL1403-100RECL1404-100

RTLRTLRTLRTLRTL

RTBCL-100RTBCL-100RTBCL-100RTBCL-100RTBCL-100

TML-ORTML-ORTML-ORTML-ORTML-OR

FK6FK6FK6FK6FK6


CL150800-100CL150200-100CL150700-100CL150300-100CL150400-100

208240277380480

50005000500050005000

RECL1508-100RECL1502-100RECL1507-100RECL1503-100RECL1504-100

RTLRTLRTLRTLRTL

RTBCL-100RTBCL-100RTBCL-100RTBCL-100RTBCL-100


FK6FK6FK6FK6FK6


ReplacementPartsFor tank-style heatersshown on page 8

Heaters with Thermostats

TemperatureRange Thermostat

ReplacementON OFF

60°F80°F100°F120°F140°F

80°F100°F120°F140°F160°F

RSU6RSU8RSU10RSU12RSU14

Adjustable 90° - 130°F RSU90-130

ReplacementBox

ElementO-Ring

ReplacementElement

ReplacementTank

MountingKit

ReplacementThermostatReplacement

Tank

ElementO-Ring

MountingKit

Check Valve

CL Heaterw/thermostat assembly

CB Heaterw/thermostat assembly

IndustrialTank

Heaters(With Power Cord)

1500 - 4000 watt

Weathertight

Single Phase



All 208v, 277v and 3000w/120v models come with cord only - no plug.

SB Models include hi-limit thermostatsand carry CSA-C/US approval.

SB Model with power cord;no thermostat

SB Model with thermostatand power cord

SL Model with power cord;no thermostat.

SL Model with thermostatand power cord.










CHART 1



Example:

Desired Temperature Range 100° - 120°FCatalog Number: Model SB1151XX-000Order as: Model SB115110-000


60°F80°F100°F120°F140°F

80°F100°F120°F140°F160°F

0608101214

AmbientAbove-20° F

AmbientBelow-20° F

Model Numberwithout

Thermostat


(see chart 1)Volts Watts Phase Amps Fig.*

No.


or Less


or Less

SB115100-000SB115800-000SB115200-000SB115700-000

SB1151XX-000SB1158XX-000SB1152XX-000SB1157XX-000

120208240277

1500150015001500

1111

12.57.26.35.4

2222


or Less


or Less

SB120100-000SB120800-000SB120200-000

SB1201XX-000SB1208XX-000SB1202XX-000

120208240

200020002000

111

16.79.68.3

222


or Less


or Less

SB122100-000SB125800-000SB125200-000SB125700-000

SB1221XX-000SB1258XX-000SB1252XX-000SB1257XX-000

120208240277

2250250025002500

1111

18.812.010.4

9.0

2222


or Less


or Less

SL130100-000SL130800-000SL130200-000SL130700-000

—SL1308XX-000SL1302XX-000SL1307XX-000

120208240277

3000300030003000

1111

25.014.412.510.8

4444

1000 —1350

Cubic Inchor Less


or Less

SL140800-000SL140200-000SL140700-000

SL1408XX-000SL1402XX-000SL1407XX-000

208240277

400040004000

111

19.216.714.4

444




Replaceable Parts

Element Tank Box PowerCord

Power Cordw/T-stat plug*

ElementO-ring

MountKit

CheckValve

SB115100-000SB115800-000SB115200-000SB115700-000

120208240277

1500150015001500

RESB1151RESB1158RESB1152RESB1157

RTBRTBRTBRTB

RTBSBRTBSBRTBSBRTBSB

RTHC1-16RTHC-16

RTHC2-16RTHC-16

RHS1-16RHS-16

RHS2-16RHS-16

TMM-ORTMM-ORTMM-ORTMM-OR

FK2FK2FK2FK2

RV-MRV-MRV-MRV-M

SB120100-000SB120800-000SB120200-000

120208240

200020002000

RESB1201RESB1208RESB1202

RTBRTBRTB

RTBSBRTBSBRTBSB

RTHC1-14RTHC-16

RTHC2-16

RHS1-14RHS-16

RHS2-16

TMM-ORTMM-ORTMM-OR

FK2FK2FK2

RV-MRV-MRV-M

SB122100-000SB125800-000SB125200-000SB125700-000

120208240277

2250250025002500

RESB1221RECB1258RECB1252RECB1257

RTBRTBRTBRTB

RTBSBRTBSBRTBSBRTBSB

RTHC1-14RTHC-16

RTHC2-16RTHC-16

RHS1-14RHS-16

RHS2-16RHS-16

TMM-ORTMM-ORTMM-ORTMM-OR

FK2FK2FK2FK2

RV-MRV-MRV-MRV-M

SL130100-000SL130800-000SL130200-000SL130700-000

120208240277

3000300030003000

RESL1301RESL1308RESL1302RESL1307

RTLRTLRTLRTL

RTBSLRTBSLRTBSLRTBSL

N/ARTHC-16

RTHC2-16RTHC-16

N/ARHS-16

RHS2-16RHS-16

TML-ORTML-ORTML-ORTML-OR

FK6FK6FK6FK6

RV-MRV-MRV-MRV-M

SL140800-000SL140200-000SL140700-000

208240277

400040004000

RESL1408RESL1402RESL1407

RTLRTLRTL

RTBSLRTBSLRTBSL

RTHC-14RTHC2-16RTHC-16

RHS-14RHS2-14RHS-16

TML-ORTML-ORTML-OR

FK6FK6FK6

RV-MRV-MRV-M

*Order this replacement cord if original heater is configured with a thermostat assembly.



ReplacementON OFF

60°F80°F100°F120°F140°F

80°F100°F120°F140°F160°F



ReplacementCord

ReplacementBox

ElementO-Ring

ReplacementElement

ReplacementTank

MountingKit


ReplacementTank

ElementO-Ring

MountingKit


Check Valve

Check Valve

ReplacementBox

ReplacementCord

ReplacementElement

SL Heaterw/thermostat assembly

SB Heaterw/thermostat assembly


WL Model without thermostat

WL Model with thermostat


IndustrialTank

Heaters1500 - 5000 watt

Weathertight

Three Phase

AmbientAbove-20° F

AmbientBelow-20° F

Model Numberwithout

Thermostat


(see chart 1)Volts Watts Ø Amp Fig.*

No.

500 CubicInch

or Less

300 CubicInch

or Less

WL315800-000WL315200-000WL315400-000

WL3158XX-000WL3152XX-000WL3154XX-000

208240480

150015001500

333

4.23.61.8

555


or Less


or Less

WL320800-000WL320200-000WL320300-000WL320400-000WL320500-000

WL3208XX-000WL3202XX-000WL3203XX-000WL3204XX-000WL3205XX-000

208240380480575

20002000200020002000

33333

5.64.83.02.42.0

55555


or Less


or Less

WL325800-000WL325200-000WL325300-000WL325400-000WL325500-000


208240380480575

25002500250025002500

33333

6.96.03.83.02.5

55555


or Less


or Less

WL330800-000WL330200-000WL330300-000WL330400-000WL330500-000


208240380480575

30003000300030003000

33333

8.37.24.63.63.0

55555


or Less


or Less

WL340800-000WL340200-000WL340300-000WL340400-000WL340500-000


208240380480575

40004000400040004000

33333

11.19.66.14.84.0

55555

1350 — 1650CubicInch

or Less

800 — 1000CubicInch

or Less

WL350800-000WL350200-000WL350300-000WL350400-000WL350500-000


208240380480575

50005000500050005000

33333

13.912.0

7.66.05.0

55555










CHART 1



Example:

Desired Temperature Range 100° - 120°FCatalog Number: Model WL3152XX-000Order as: Model WL315210-000


use a controlbox



60°F80°F100°F120°F140°F

80°F100°F120°F140°F160°F

0608101214

Adjustable 90° - 130°F A3





ReplacementON OFF

60°F80°F100°F120°F140°F

80°F100°F120°F140°F160°F



Model Number Volts Watts Replaceable Parts

Element Tank ElementO-ring

MountingKit

CheckValve

WL315800-000WL315200-000WL315400-000

208240480

150015001500

E01583W-15NT-00E01523W-15NT-00E01543W-15NT-00

RTLRTLRTL

TML-ORTML-ORTML-OR

FK6FK6FK6

RV-MRV-MRV-M

WL320800-000WL320200-000WL320300-000WL320400-000WL320500-000

208240380480575

20002000200020002000

E02083W-25NT-00E02023W-25NT-00E02033W-25NT-00E02043W-25NT-00E02053W-25NT-00

RTLRTLRTLRTLRTL


FK6FK6FK6FK6FK6


WL325800-000WL325200-000WL325300-000WL325400-000WL325500-000

208240380480575

25002500250025002500


RTLRTLRTLRTLRTL


FK6FK6FK6FK6FK6


WL330800-000WL330200-000WL330300-000WL330400-000WL330500-000

208240380480575

30003000300030003000


RTLRTLRTLRTLRTL


FK6FK6FK6FK6FK6


WL340800-000WL340200-000WL340300-000WL340400-000WL340500-000

208240380480575

40004000400040004000


RTLRTLRTLRTLRTL


FK6FK6FK6FK6FK6


WL350800-000WL350200-000WL350300-000WL350400-000WL350500-000

208240380480575

50005000500050005000


RTLRTLRTLRTLRTL


FK6FK6FK6FK6FK6


ReplacementTank

MountingKit

ElementO-Ring


Check Valve

ReplacementElement

WL Heaterw/thermostat assembly


Technical Drawingsall dimensions in inches

WL Style Heater without thermostat (pg. 12-13) FIGURE 5 WL Style Heater with thermostat (pg. 12-13)

CB Style Heater without thermostat (pg. 8-9) FIGURE 1 CB Style Heater with thermostat (pg. 8-9)

SB Style Heater without thermostat (pg. 10-11) FIGURE 2 SB Style Heater with thermostat (pg. 10-11)

CL Style Heater without thermostat (pg. 8-9) FIGURE 3 CL Style Heater with thermostat (pg. 8-9)

SL Style Heater without thermostat (pg. 10-11) FIGURE 4 SL Style Heater with thermostat (pg. 10-11)

1"NPT FemaleOutlet

5.75

20.73

3.85

16.17

5.75

1"NPT FemaleOutlet

3.85 4.06

3.754.35

4.90

5.26

1"NPT FemaleInlet

1"NPT MaleInlet

18.8713.88

ADJUSTABLE1" NPTFemaleOutlet

5.25

4.21

2.5

5.0

23.018.0

ADJUSTABLE1" NPTFemaleOutlet

8.15.5

6.2

1"NPT FemaleInlet

1"NPT MaleInlet

5.255.254.21

2.5 2.5

5.0 5.0 5.3

1" NPTFemaleOutlet

1" NPTFemaleOutletADJUSTABLE ADJUSTABLE

17.9 23.17

13.88 18.08

1"NPT FemaleInlet

1"NPT MaleInlet

19.48

13.88

ADJUSTABLE ADJUSTABLE

23.818.2

1" NPT FemaleOutlet

1" NPT FemaleOutlet

2.5

5.254.25

2.55.0

6.2

2.6

6.4

7.2

1"NPT FemaleInlet

1"NPT MaleInlet

17.20

4.00 5.75

1"NPT FemaleOutlet

1"NPT FemaleOutlet

4.90 4.06

3.754.35

8.43 5.75

21.67

4.90

3.132.48

4.39

1"NPT MaleInlet

1"NPT FemaleInlet

4.06


IndustrialTankHeatersOriginal EquipmentReplacement Heaters

ThermostatTemperature Setting

Adjustment(70°F - 210°F)

Adjustable ThermostatConfiguration

CSA and UL approved

HeaterOrientation

• Large NEMA 4 enclosure with 1/2” and 3/4” knockouts.

• Rubber insulating sleeve around tank.

• Internal adjustable thermostat. Adjustable setpoints from 70°F - 210°F.

• Incoloy sheath elements.

• Four wattage/voltage options. Three corresponding to Caterpillar part numbers.

• Vertical mount only.

For Original Equipment Replacement:

• Two 5” stainless steel worm-drive clamps are included to mount heater to existing bracket.

For New Installations:

• U-bolt mounting brackets are available. Order kit part number: FK9.

* Part Number changed to 2006504

HOTSTARTPart Number

Caterpillar Part Number

Wattage Voltage Pre-wired atAssembly

ReplacementElement

CL130DA2-000 7E-6247 3kw 120/240 VAC 120V RECL130D

CL160EA2-000 7E-6248* 6kw 240/480 VAC 240V RECL160E

CL160CA2-000 7E-6249 6kw 120 VAC 2-120V Circuits RECL160C

CL140EA2-000 — 4kw 240/480 VAC 240V RECL140E


ForcedCirculating

HeatingSystem

With 10 GPM Pump

CSM Model

For Engines From 1000to 6000 CID

These systems have proven tobe a superior method ofpreheating engines thatnormally require the use oftwo thermosiphon heaters.

Forced circulation offersmany benefits overthermosiphon units.• Reduced electrical

consumption

• Even heating over entirecooling system

• Reduced temperature atoutlet extends hose life

• Longer heating element life

• Control circuitry pre-wired foreasy installation

• UL-C/US listed (60Hz models) and CEcompliant (50Hz models).

• 90°-130°F/32°-55°C adjustablethermostat.

The CSM operates automatically by supplying a 24 Volt DC signal to the providedcontacts.

Field testing has shown substantial energy savings in comparison to traditional thermosiphon heating methods.

• Small, compact design for easyinstallation.

• Meets requirements for installation onany UL 2200 listed generator

Engine SizeCID Liter

Part Number Wattage Voltage Phase Hz Amps

1000to

200015-30

CSM10301-000CSM10308-000CSM1030C-000CSM10302-000

3000300030003000

120208220240

1111

60605060

27.016.415.614.5

2000

to

3000

25-50

CSM10608-000CSM1060C-000CSM10602-000CSM10604-000CSM30603-000CSM30604-000

600060006000600060006000

208220240480380480

111133

605060605060

30.829.327.014.511.19.2

3000

to

4500

50-75

CSM10908-000CSM1090C-000CSM10902-000CSM10904-000CSM30903-000CSM30904-000

900090009000900090009000

208220240480380480

111133

605060605060

45.342.939.520.815.712.8

4500

to

6000

75-100

CSM11202-000CSM11204-000CSM31203-000CSM31204-000

12000120001200012000

240480380480

1133

60605060

52.027.020.316.5

Other voltages available. Consult the factory.


SystemDrawingsCSM Dimensions

Shipping Weight: 37lbs. (16.8kg)

Shipping Weight: 54lbs. (24.5kg)

1Ø or 3ØOver 240v

1Ø240v or Less

* For CE compliant models, overalldepth measures 10.8” (274mm)


19

Section 2

Industrial Tank StyleCoolant Heaters

Hazardous Location


EE Model assembled withthermostat.

EE Model without thermostat.


IndustrialTank Heaters

1500 - 5000 watt

Hazardous Location

Single Phase

INSTALLATION TIPSFor the use of 3/4” or 1” ID heater hose, hose barb

adapters are available. See below.




CHART 1



Example:

Desired Temperature Range 100° - 120°FCatalog Number: Model EE1151XX-000Order as: Model EE115110-000


use a controlbox



60°F80°F100°F120°F140°F

80°F100°F120°F140°F160°F

0608101214

AmbientAbove-20° F

AmbientBelow-20° F

Model Numberwithout

Thermostat

Fig.*No.

Model Numberwith Thermostat

(see chart 1)

Fig.*No. Volt Watt Ø Amp

500 CubicInch

or Less

300 CubicInch

or Less

EE115100-000EE115800-000EE115200-000EE115700-000EE115300-000EE115400-000EE115500-000

1111111

EE1151XX-000EE1158XX-000EE1152XX-000EE1157XX-000EE1153XX-000EE1154XX-000EE1155XX-000

2222222

120208240277380480575

1500150015001500150015001500

1111111

12.57.26.35.43.93.12.6

500 - 600Cubic Inch

or Less

300 - 400Cubic Inch

or Less

EE120100-000EE120800-000EE120200-000EE120300-000EE120400-000EE120500-000

111111

EE1201XX-000EE1208XX-000EE1202XX-000EE1203XX-000EE1204XX-000EE1205XX-000

222222

120208240380480575

200020002000200020002000

111111

16.79.68.35.34.23.5

600 - 800Cubic Inch

or Less

400 - 500Cubic Inch

or Less

EE125100-000EE125800-000EE125200-000EE125700-000EE125300-000EE125400-000EE125500-000

1111111


2222222

120208240277380480575

2500250025002500250025002500

1111111

20.812.010.4

9.26.65.24.3

800 - 1000Cubic Inch

or Less

500 - 600Cubic Inch

or Less

EE130100-000EE130800-000EE130200-000EE130700-000EE130300-000EE130400-000EE130500-000

1111111


2222222

120208240277380480575

3000300030003000300030003000

1111111

25.014.412.510.8

7.96.35.2


or Less

600 - 800Cubic Inch

or Less

EE140800-000EE140200-000EE140700-000EE140300-000EE140400-000EE140500-000

111111


222222

208240277380480575

400040004000400040004000

111111

19.216.714.410.5

8.37.0

1350 - 1650CubicInch

or Less

800 - 1000CubicInch

or Less

EE150800-000EE150200-000EE150700-000EE150300-000EE150400-000EE150500-000

111111


222222

208240277380480575

500050005000500050005000

111111

24.020.818.113.210.4

8.7





ReplacementON OFF

60°F80°F100°F120°F140°F

80°F100°F120°F140°F160°F



Replaceable Parts

Element MI Cable Tank Flange FlangeO-ring

MountKit

CheckValve

EE115100-000EE115800-000EE115200-000EE115700-000EE115300-000EE115400-000EE115500-000

120208240277380480575

1500150015001500150015001500

REEE1151REEE1158REEE1152REEE1157

E01531E-50NA-00E01541E-50NA-00E01551E-50NA-00

PRP104202-024PRP104202-024PRP104202-024PRP104202-024PRP104202-024PRP104202-024PRP104202-024

RTLRTLRTLRTLRTLRTLRTL

RF-LRF-LRF-LRF-LRF-LRF-LRF-L

TML-ORTML-ORTML-ORTML-ORTML-ORTML-ORTML-OR

FK6FK6FK6FK6FK6FK6FK6

RV-MRV-MRV-MRV-MRV-MRV-MRV-M

EE120100-000EE120800-000EE120200-000EE120300-000EE120400-000EE120500-000

120208240380480575

200020002000200020002000

REEE1201REEE1208REEE1202

E02031E-50NA-00E02041E-50NA-00E02051E-50NA-00

PRP104202-024PRP104202-024PRP104202-024PRP104202-024PRP104202-024PRP104202-024

RTLRTLRTLRTLRTLRTL

RF-LRF-LRF-LRF-LRF-LRF-L


FK6FK6FK6FK6FK6FK6


EE125100-000EE125800-000EE125200-000EE125700-000EE125300-000EE125400-000EE125500-000

120208240277380480575

2500250025002500250025002500


E02531E-C0NA-00E02541E-C0NA-00E02551E-C0NA-00







EE130100-000EE130800-000EE130200-000EE130700-000EE130300-000EE130400-000EE130500-000

120208240277380480575

3000300030003000300030003000


E03031E-50NA-00E03041E-50NA-00E03051E-50NA-00







EE140800-000EE140200-000EE140700-000EE140300-000EE140400-000EE140500-000

208240277380480575

400040004000400040004000

REEE1408REEE1402REEE1407

E04031E-50NA-00E04041E-50NA-00E04051E-50NA-00


RTLRTLRTLRTLRTLRTL



FK6FK6FK6FK6FK6FK6


EE150800-000EE150200-000EE150700-000EE150300-000EE150400-000EE150500-000

208240277380480575

500050005000500050005000

E05081E-50NA-00E05021E-50NA-00E05071E-C0NA-00E05031E-C0NA-00E05041E-C0NA-00E05051E-C0NA-00


RTLRTLRTLRTLRTLRTL



FK6FK6FK6FK6FK6FK6


ReplacementTank

MountingKit

Flange &O-Ring


Check ValveReplacementElement

MI Cable

EE Heaterw/thermostat assembly



INSTALLATION TIPSFor the use of 3/4” or 1” ID heater hose, hose barb

adapters are available. See below.




CHART 1



Example:

Desired Temperature Range 100° - 120°FCatalog Number: Model EE3152XX-000Order as: Model EE315210-000


use a controlbox



60°F80°F100°F120°F140°F

80°F100°F120°F140°F160°F

0608101214

AmbientAbove-20° F

AmbientBelow-20° F

Model Numberwithout

Thermostat

Fig.*No.


(see chart 1)

Fig.*No. Volt Watts Ø Amp

500 CubicInch

or Less

300 CubicInch

or Less

EE315800-000EE315200-000EE315400-000

111

EE3158XX-000EE3152XX-000EE3154XX-000

222

208240480

150015001500

333

4.23.61.8

500 - 600Cubic Inch

or Less

300 - 400Cubic Inch

or Less

EE320800-000EE320200-000EE320300-000EE320400-000EE320500-000

11111

EE3208XX-000EE3202XX-000EE3203XX-000EE3204XX-000EE3205XX-000

22222

208240380480575

20002000200020002000

33333

5.64.83.02.42.0

600 - 800Cubic Inch

or Less

400 - 500Cubic Inch

or Less

EE325800-000EE325200-000EE325300-000EE325400-000EE325500-000

11111


22222

208240380480575

25002500250025002500

33333

6.96.03.83.02.5


or Less

500 - 600Cubic Inch

or Less

EE330800-000EE330200-000EE330300-000EE330400-000EE330500-000

11111


22222

208240380480575

30003000300030003000

33333

8.37.24.63.63.0


or Less

600 - 800Cubic Inch

or Less

EE340800-000EE340200-000EE340300-000EE340400-000EE340500-000

11111


22222

208240380480575

40004000400040004000

33333

11.19.66.14.84.0

1350 - 1650CubicInch

or Less

800 - 1000CubicInch

or Less

EE350800-000EE350200-000EE350300-000EE350400-000EE350500-000

11111


22222

208240380480575

50005000500050005000

33333

13.912.0

7.66.05.0

EE Model assembled withthermostat.

EE Model without thermostat.

IndustrialTank Heaters

1500 - 5000 watt

Hazardous Location

Three Phase





ReplacementON OFF

60°F80°F100°F120°F140°F

80°F100°F120°F140°F160°F



Replaceable Parts

Element MI Cable Tank Flange FlangeO-ring

MountKit

CheckValve

EE315800-000EE315200-000EE315400-000

208240480

150015001500

E01583E-15NA-00E01523E-15NA-00E01543E-15NA-00

PRP104202-024PRP104202-024PRP104202-024

RTLRTLRTL

RF-LRF-LRF-L

TML-ORTML-ORTML-OR

FK6FK6FK6

RV-MRV-MRV-M

EE320800-000EE320200-000EE320300-000EE320400-000EE320500-000

208240380480575

20002000200020002000

E02083E-25NA-00E02023E-25NA-00E02033E-25NA-00E02043E-25NA-00E02053E-25NA-00

PRP104202-024PRP104202-024PRP104202-024PRP104202-024PRP104202-024

RTLRTLRTLRTLRTL

RF-LRF-LRF-LRF-LRF-L


FK6FK6FK6FK6FK6


EE325800-000EE325200-000EE325300-000EE325400-000EE325500-000

208240380480575

25002500250025002500



RTLRTLRTLRTLRTL



FK6FK6FK6FK6FK6


EE330800-000EE330200-000EE330300-000EE330400-000EE330500-000

208240380480575

30003000300030003000



RTLRTLRTLRTLRTL



FK6FK6FK6FK6FK6


EE340800-000EE340200-000EE340300-000EE340400-000EE340500-000

208240380480575

40004000400040004000



RTLRTLRTLRTLRTL



FK6FK6FK6FK6FK6


EE350800-000EE350200-000EE350300-000EE350400-000EE350500-000

208240380480575

50005000500050005000



RTLRTLRTLRTLRTL



FK6FK6FK6FK6FK6


ReplacementTank

MountingKit

Flange &O-Ring


Check Valve

ReplacementElement

MI Cable

EE Heaterw/thermostat assembly

Technical Drawingsall dimensions in inches

FIGURE 2

FIGURE 1

2.5

4.2

5.35.0

2.5

5.0

20.3

13.9

ADJUSTABLE

1" NPT Outlet

1" NPT Inlet

9.2

6.75

1/2" Conduit Opening1" NPT Inlet

5.32

2.09

24.77

ADJUSTABLE

1" NPT outlet

6.3

EE Style Heater without thermostat (pg. 20 and 22)

EE Style Heater with thermostat (pg. 20 and 22)

HOTSTART Engine Heating P.O. Box 11245 Spokane Valley, WA 99211-024524

25

Section 3

Industrial Oil Heaters

Industrial ImmersionHeaters – Thread-in styleand threadless V-clampstyle

DC Oil Heaters

Temperature Controls


NOTES: Weathertight heaters are standard with a 4 ft. oil and heat resistant power cord - no plug.

Class 1, Group D heaters are standard with 18” of lead wire for connection to the power leads in an approvedsplice box.

For Class 1, Group D thermostats, see page 32.

Oil Heaters

OilCapacity

WeathertightHeater Only

Weathertight With Thermostat(see chart p. 27)

Class 1, Group DHazardous Locations

Heater OnlyVolts Watts Amps Watts Per

Square Inch

3/8” N.P.T. THREAD WITH A 2 1/8” PROBE LENGTH

2 Quartsor Less

OW005100-000OW005200-000

——

——

120240

5050

.4

.220.020.0

1/2” N.P.T. THREAD WITH A 4” PROBE LENGTH

2 Quartsto

6 Quarts

OW212100-000OW212200-000

OW2121XX-000OW2122XX-000

OE212100-000OE212200-000

120240

125125

1.0.5

24.624.6

3/4” N.P.T. THREAD WITH A 5” PROBE LENGTH

1 Gallonto

5 Gallons

OW415100-000OW415200-000

OW4151XX-000OW4152XX-000

OE415100-000OE415200-000

120240

150150

1.3.6

14.614.6

5 Gallonsto

15 Gallons

OW430100-000OW430800-000OW430200-000

OW4301XX-000OW4308XX-000OW4302XX-000

OE430100-000OE430800-000OE430200-000

120208240

300300300

2.61.11.2

29.329.329.3

1” N.P.T. THREAD WITH A 5 1/4” PROBE LENGTH

1 Gallonto

5 Gallons

OW615100-000OW615200-000

OW6151XX-000OW6152XX-000

OE615100-000OE615200-000

120240

150150

1.3.6

10.710.7

5 Gallonsto

15 Gallons

OW630100-000OW630800-000OW630200-000OW630700-000

——

OW6301XX-000OW6308XX-000OW6302XX-000OW6307XX-000

——

OE630100-000OE630800-000OE630200-000OE630700-000OE630300-000OE630400-000

120208240277380480

300300300300300300

2.61.61.21.11.0

.6

21.421.421.421.421.421.4

15 Gallonsto

30 Gallons

OW650100-000OW650800-000OW650200-000OW650700-000

———

OW6501XX-000OW6508XX-000OW6502XX-000OW6507XX-000

———

OE650100-000OE650800-000OE650200-000OE650700-000OE650300-000OE650400-000OE650500-000

120208240277380480575

500500500500500500500

4.12.42.01.81.31.00.8

35.735.735.735.735.735.735.7

WEATHERTIGHT

heater only

CLASS 1, GROUP D

heater only

Use a thermostat with all lube oil heaters to protect the oilfrom overheating if the heater is energized while the engine ishot or running.

Lube oil heaters must always be installed in the sump with theentire heater submerged below the oil level at all times.

For Class 1, Group D thermostats, see page 32.

Heaters with Y-type harness and thermostat (see page 32 for drawings with dimensions)

120 Volt and 240 Volt are complete with a 3-prong plug.

HOTSTART Assembled Lube Oil Heaters eliminate the need forsplice boxes or field wiring of the thermostat and heater.

Always mount the thermostat above and to one side of theheater for the most efficient control.

for hazardous locations

Thermostat

6.75.25

Probe Depth

1" Dia.

1" NPT1 3/8 Std. Hex

1-14 UNS

7.75

4.00Probe Depth

1/2" NPT

1.972.40

3/4" NPT x 1/2" NPT

Reducer

8.89

3/4" NPT x 1/2" NPT

5.00Probe Depth

3/4" NPT

1.972.40

Reducer

9.20

3/4" NPT x 1/2" NPT

5.25Probe Depth

1" NPT

1.972.40

Reducer

6.45.00

Probe Depth

3/4 Dia.

3/4" NPT

1 3/8 Std. Hex

1-14 UNS

Customer Support: (509) 536-8660 Toll-Free FAX: (800) 224-5550 www.hotstart.com 27

6.54.00

Probe Depth

.50 Dia.

1/2" NPT

1 3/8 Std. Hex1-14 UNS

OIL HEATERS WITH THERMOSTATS

To specify temperature range of thermostat, insert numerical code from chart in place ofthe XX in model number.

Example:

Desired Temperature Range 100° - 120°Catalog Number: Model OW2121XX-000Order as: Model OW212110-000

NUMERICAL CODE

TEMPERATURERANGE SWITCH CAPACITY THREAD

SIZEOn Off

06

08

10

12

60°F

80°F

100°F

120°F

80°F

100°F

120°F

140°F

120V - 15 Amps

208V - 10 Amps

240V - 10 Amps

277V - 10 Amps

1/2”N.P.T.

HOTSTART Engine Heating P.O. Box 11245 Spokane Valley, WA 99211-0245

Class I, Group D heaters with thermostat for hazardous locations also available. Substitute the letter “W” in part number with the letter “E” to specify Class I, Group D heaters.

Industrial Immersion Heaters are also available for coolants and other process heating. Call factory.

IndustrialImmersionHeaters

Models for larger capacities than shown are available. Call factory.

With Fixed-Setting,For: Lube Oils, Built-In Thermostat (Pg. 29)

Hydraulics and or Adjustable Weather TightDiesel Fuels Thermostat (Pg. 31) NEMA 4 Enclosure

2” Screw Plug

28

Oil CapacityHIGH LIMIT THERMOSTAT CONTROL SETTING

Volts Watts Amps Watts Sq. In.

On 60° F / Off 80° F On 80° F / Off 100° F On 100° F / Off 120° F

SINGLE PHASE — 2” N.P.T. WITH A 12” PROBE LENGTH

30 to 45Gallons

E01011W-156A-00E01081W-156A-00E01021W-156A-00E01071W-156A-00

E01011W-158A-00E01081W-158A-00E01021W-158A-00E01071W-158A-00

E01011W-151A-00E01081W-151A-00E01021W-151A-00E01071W-151A-00

120208240277

1000100010001000

8.34.84.23.6

17.017.017.017.0

45 to 60Gallons

E01511W-156A-00E01581W-156A-00E01521W-156A-00E01571W-156A-00

E01511W-158A-00E01581W-158A-00E01521W-158A-00E01571W-158A-00

E01511W-151A-00E01581W-151A-00E01521W-151A-00E01571W-151A-00

120208240277

1500150015001500

12.57.26.35.4

17.017.017.017.0

THREE PHASE — 2” N.P.T. WITH A 12” PROBE LENGTH

30 to 45Gallons

E01083W-106A-00E01023W-106A-00E01033W-106A-00

E01083W-108A-00E01023W-108A-00E01033W-108A-00

E01083W-101A-00E01023W-101A-00E01033W-101A-00

208240380

100010001000

2.82.41.5

11.011.011.0

45 to 60Gallons

E01583W-156A-00E01523W-156A-00E01533W-156A-00E01543W-156A-00

E01583W-158A-00E01523W-158A-00E01533W-158A-00E01543W-158A-00

E01583W-151A-00E01523W-151A-00E01533W-151A-00E01543W-151A-00

208240380480

1500150015001500

4.23.62.31.8

17.017.017.017.0

SINGLE PHASE — 2” N.P.T. WITH A 18” PROBE LENGTH

60 to 90Gallons

E02011W-156A-00E02081W-156A-00E02021W-156A-00E02071W-156A-00E02031W-156A-00E02041W-156A-00



120208240277380480

200020002000200020002000

16.79.68.47.25.34.2

14.014.014.014.014.014.0

THREE PHASE — 2” N.P.T. WITH A 18” PROBE LENGTH

60 to 90Gallons

E02083W-156A-00E02023W-156A-00E02033W-156A-00E02043W-156A-00

E02083W-158A-00E02023W-158A-00E02033W-158A-00E02043W-158A-00

E02083W-151A-00E02023W-151A-00E02033W-151A-00E02043W-151A-00

208240380480

2000200020002000

5.64.83.02.4

14.014.014.014.0


1.0

2" NPT

3.2512" OR 18" DIM

3.60

Thermostat Sensor

Heat Shrink Cover

Sensor Seat

FIXED THERMOSTAT ASSEMBLY

HOTSTART immersion heaters are complete with a fixed-setting, built-in thermostat(shown below). All models are also available with an adjustable thermostat (pg. 31).

Ideal for heating hydraulic reservoirs on construction equipment and the sumps of largeindustrial engines.

TYPICAL WIRING DIAGRAMS

Three phase and single phase above 277 VAC Single phase 277 VAC and below

NOTES:

On applications where level offluid is subject to change, aliquid level switch mounted aminimum of 3 to 4 inchesabove element isrecommended. Liquid levelswitch is not included withheater.

All 380 Volt and 480 Voltheaters must be used inconjunction with contactor andcontrol transformer.

All three phase heaters must beused with a contactor. Seepages 37 & 38.

Higher or lower temperatureranges are available. ConsultHOTSTART.

“W” Weathertight ModelNEMA 4

IndustrialImmersionHeaters2” Screw Plug

PowerIn

PowerIn

Ground GroundFuse

Fuse

Transformer

LiquidLevel

Switch

LiquidLevel

Switch

Temp.Control

Temp.Control

ElementContactor Coil

HeatingElement

HeatingElement

“E” Hazardous Location ModelNEMA 4 & 7

ELECTRICAL RATING

15 Amps at 120 VAC10 Amps at 240 VAC10 Amps at 277 VAC

4.4

12" OR 18" DIM

2" NPT

1.3 4.3



Thermostat assembly shown in “EP” housing.

IndustrialImmersionHeaters

Class I, Group D heaters with thermostat for hazardous locations also available. Substitute the letter “W” in part number with the letter “E” to specify Class I, Group D heaters.

Industrial Immersion Heaters are also available for coolants and other process heating. Call factory.

Models for larger capacities than shown are available. Call factory.

V-Clamp Threadless Design


With Fixed-Setting,For: Lube Oils, Built-In Thermostat (Pg. 29)

Hydraulics and or Adjustable Weather TightDiesel Fuels Thermostat (Pg. 31) NEMA 4 Enclosure

Oil CapacityHIGH LIMIT THERMOSTAT CONTROL SETTING

Volts Watts Amps Watts Sq. In.

On 60° F / Off 80° F On 80° F / Off 100° F On 100° F / Off 120° F

SINGLE PHASE — WITH A 12” PROBE LENGTH

30 to 45Gallons

E01011W-156V-00E01081W-156V-00E01021W-156V-00E01071W-156V-00

E01011W-158V-00E01081W-158V-00E01021W-158V-00E01071W-158V-00

E01011W-151V-00E01081W-151V-00E01021W-151V-00E01071W-151V-00

120208240277

1000100010001000

8.34.84.23.6

17.017.017.017.0

45 to 60Gallons

E01511W-156V-00E01581W-156V-00E01521W-156V-00E01571W-156V-00

E01511W-158V-00E01581W-158V-00E01521W-158V-00E01571W-158V-00

E01511W-151V-00E01581W-151V-00E01521W-151V-00E01571W-151V-00

120208240277

1500150015001500

12.57.26.35.4

17.017.017.017.0

THREE PHASE — WITH A 12” PROBE LENGTH

30 to 45Gallons

E01083W-106V-00E01023W-106V-00E01033W-106V-00

E01083W-108V-00E01023W-108V-00E01033W-108V-00

E01083W-101V-00E01023W-101V-00E01033W-101V-00

208240380

100010001000

2.82.41.5

11.011.011.0

45 to 60Gallons

E01583W-156V-00E01523W-156V-00E01533W-156V-00E01543W-156V-00

E01583W-158V-00E01523W-158V-00E01533W-158V-00E01543W-158V-00

E01583W-151V-00E01523W-151V-00E01533W-151V-00E01543W-151V-00

208240380480

1500150015001500

4.23.62.31.8

17.017.017.017.0

SINGLE PHASE — WITH A 18” PROBE LENGTH

60 to 90Gallons

E02011W-156V-00E02081W-156V-00E02021W-156V-00E02071W-156V-00E02031W-156V-00E02041W-156V-00



120208240277380480

200020002000200020002000

16.79.68.47.25.34.2

14.014.014.014.014.014.0

THREE PHASE — WITH A 18” PROBE LENGTH

60 to 90Gallons

E02083W-156V-00E02023W-156V-00E02033W-156V-00E02043W-156V-00

E02083W-158V-00E02023W-158V-00E02033W-158V-00E02043W-158V-00

E02083W-151V-00E02023W-151V-00E02033W-151V-00E02043W-151V-00

208240380480

2000200020002000

5.64.83.02.4

14.014.014.014.0


V-ClampIndustrialImmersionHeaterThreadless Design

HOTSTART immersion heaters are complete with afixed-setting, built-inthermostat (shown on page29). All models are availablewith an adjustable thermostat(shown below). Consult factoryfor model number.

Ideal for heating hydraulicreservoirs on constructionequipment and the sumps oflarge industrial engines.

CoverGasket

Fasteners, CoverGround Screw

Ground Lug

Thermostat

Element Assembly

ADJUSTABLE THERMOSTAT ASSEMBLY

Call HOTSTART for complete model number featuring adjustable thermostat.

NOTE: Replacement elements supplied with “O” Ringonly. For new installations, order kit - P/N VC-SK. Kit Includes:

1 – steel weldable adapter1 – worm-drive V-Clamp1 – “O” Ring

NOTES:

On applications where level offluid is subject to change, aliquid level switch mounted aminimum of 3 to 4 inchesabove element isrecommended. Liquid levelswitch is not included withheater.

All 380 Volt and 480 Voltheaters must be used inconjunction with contactor andcontrol transformer.

All three phase heaters must beused with a contactor. Seepages 37 & 38.

Higher or lower temperatureranges are available. ConsultHOTSTART.

O-ring

V-Clamp

3.7212”or 18” DIM

Weldable Adapter

3.60



TEMPERATURE RANGE

OFF 70°F to 210°F

ELECTRICAL RATING

30 Amps at 125 VAC

30 Amps at 240 VAC

30 Amps at 277 VAC

20 Amps at 480 VAC

Nominal thermal differential is 8°F


12 Volt and 24 Volt DC oil heaters can be powered directly from the battery, but will drainthe battery very rapidly unless charged by an alternator or generator.

NOTE: Heater amperage as shown in the table above will determine the life of thebattery — (Amps x Hours = Amp hours).

Example: A 12.5 Amp heater will completelydrain a 100 Amp-hour battery in 8 hours.

DC OilHeaters12 and 24 volt

Please see page 27 for photos and technical drawings of “OW” and “OE” style oil heaters.

Lube oil temperature controls hold lube oil at the desired temperature.

If the heater is energized while the engine is hot or running, Kim Hotstart recommendsusing thermostats with all lube oil heaters to protect the oil from overheating.

The sensing unit can be changed without draining the sump.

-

+

12 or 24VDC

DIT COIL

C1

C1 C1

MagneticContactors

Oil Heater

100 Amp-hour

12.5 Amp= 8 Hours

TemperatureControls

When used with athermostat

control, all DC oilheaters must use

a DC relay

Class I, Group DHazardousLocation

Weathertight

Weathertight models are furnishedwith a 3 ft. 16/3 HPN power cord. Class I,Group D model is furnished with 18” oflead wire for connection to the power

leads in an approved splice box.

3.375

1.625 1.75Probe Depth

.600

.5 NPT

3' 16-3HPN Cord

5.50

3.25 .600

1.625ProbeDepth

.5 Inch NPT

Weathertight Model Dimensions Class 1, Group Model Dimensions

Oil Capacity Volts Watts

HOTSTART Model Numbers

AmpsWatts Per

SquareInch

1/2” N.P.T. With a 4” Probe Length

3/4” N.P.T. With a 4 7/8” Probe

Length

1” N.P.T. With a 5 3/8” Probe

Length

2 Quartsor Less

1224

7575

OW207900-012OW207900-024

OW407900-012OW407900-024

——

6.33.1

1/2” are all 14.7 WSI3/4” are all 7.3 WSI

2 to 6Quarts 24 125 OW212900-024 — — 5.2 24.6 WSI

1 to 5Gallons

1224

150150

——

OW415900-012OW415900-024

OW615900-012OW615900-024

12.56.3

3/4” are all 14.6 WSI1” are all 10.7 WSI

5 to 15Gallons

1224

300300

——

—OW430900-024

OW630900-012OW630900-024

25.012.5

3/4” are all 29.3 WSI1” are all 21.4 WSI

15 to 30Gallons 24 500 — — OW650900-024 20.8 35.7 WSI

Weathertight Model Number

Class I, Group D Model Number

Temp. RangeOn Off

ThreadSize

SwitchCapacity

DIT68DIT810DIT1012DIT1214

DIT68EPDIT810EPDIT1012EPDIT1214EP

60°F 80°F80°F 100°F

100°F 120°F120°F 140°F

1/2” N.P.T.1/2” N.P.T.1/2” N.P.T.1/2” N.P.T.

120v - 15 amps208v - 10 amps240v - 10 amps277v - 10 amps

12v DC24v DC

PilotDutyOnly}

12 VOLT/24 VOLT DC CONTROL BOXES

25 AmpsMaximum

12V24V

JBMC330DC-12VJBMC330DC-24V

33

Section 4

Thermostat Controls

Pressure Switch

Magnetic Contactors

Junction Boxes

Complete ControlSystems – for manual and automatic startengines


Fixed SettingTemperatureControls

Weathertight

NOTE: When using athermostat above 277 volt

or on 3 phase applications,

select the proper controlbox with transformer and

contactor as shown onpages 37 or 38.

3.62

1" NPT 1" NPT4.57

4.71

1/2 Conduit Knockout (4X)

3.62

4.96

4.62

1" Hose Barb

1 3/8" Hex

1" NPT

1/2" ConduitKnockout (4X)

3.62

4.96

4.62

1 3/8" Hex

3/4" Hose Barb

1" NPT

1.25

2.25

1" NPT Inlet1.0

5.0

1/2" NPT Conduit Opening

3.0

1”NPT x 1”NPTCONDUIT TYPE ENCLOSURE

Part Number

Temp. Setting

Maximum CapacityRatings

On Off 120/240Volt 277 Volt

TFTC6-1NPTTFTC8-1NPT

TFTC10-1NPTTFTC12-1NPTTFTC14-1NPT

60°F80°F

100°F120°F140°F

80°F100°F120°F140°F160°F

25 amps25 amps25 amps25 amps25 amps


1”NPT x 1” HOSE BARBCONDUIT TYPE ENCLOSURE

Part Number

Temp. Setting



TFTC6-1HBTFTC8-1HB

TFTC10-1HBTFTC12-1HBTFTC14-1HB

60°F80°F

100°F120°F140°F

80°F100°F120°F140°F160°F



1”NPT x 3/4” HOSE BARBCONDUIT TYPE ENCLOSURE

Part Number

Temp. Setting



TFTC6-3HBTFTC8-3HB

TFTC10-3HBTFTC12-3HBTFTC14-3HB

60°F80°F

100°F120°F140°F

80°F100°F120°F140°F160°F



CLASS 1, GROUP DCONDUIT TYPE ENCLOSURE

Part Number

Temp. Setting



TFT6ERTFT8ER

TFT10ERTFT12ERTFT14ER

60°F80°F

100°F120°F140°F

80°F100°F120°F140°F160°F




TemperatureControlsWeathertight

NOTE: When using athermostat above 277 voltor on 3 phase applications,select the proper control boxwith transformer andcontactor as shown onpages 37 or 38.

4.71

1"NPT

14-3 HPN(4 FT.)

3.30

2.56

1"NPT

14-3 HPN (4 FT.)

1 3/8" HEX

1" Hosebarb

3.78

4.96

1" NPT

2.63

14-3 HPN (4 FT.)

1 3/8" HEX

3/4"Hosebarb

3.78

4.96

2.63

1" NPT

60 95

125

155

185

215250

LO

3.061.87

.93

3.36

.078Dia.

5.06

6.38

1.03

1”NPT x 1”NPTCORD TYPE ENCLOSURE

Part Number

Temp. Setting



TFT6-1NPTTFT8-1NPT

TFT10-1NPTTFT12-1NPTTFT14-1NPT

60°F80°F

100°F120°F140°F

80°F100°F120°F140°F160°F



1”NPT x 1” HOSE BARBCORD TYPE ENCLOSURE

Part Number

Temp. Setting



TFT6-1HBTFT8-1HB

TFT10-1HBTFT12-1HBTFT14-1HB

60°F80°F

100°F120°F140°F

80°F100°F120°F140°F160°F



1”NPT x 3/4” HOSE BARBCORD TYPE ENCLOSURE

Part Number

Temp. Setting



TFT6-3HBTFT8-3HB

TFT10-3HBTFT12-3HBTFT14-3HB

60°F80°F

100°F120°F140°F

80°F100°F120°F140°F160°F



REMOTE-MOUNTADJUSTABLE

With 60’’ Capillary Probe

Part Number

Adjustable Range65°F to 250° (Open or Off Setting)

Differential 7°F (Close or On Setting)

AT6525Maximum Capacity Ratings

120/240 Volt – 25 Amps277 Volt – 22 Amps

ATWAluminumProtective

Well forAT6525

.5 inchNPT


TemperatureControls

AdjustableThermostat

Reduce engine heater cycle time

in both warm and cold ambient

temperatures.

HOTSTART offers an adjustable thermostatas an option on weathertight enginepreheaters and as a stand-alone unit.Control your optimum desiredtemperature with Kim Hotstart’sadjustable thermostat.

• Adjustable from 90°F to 130°F.

• Stock one thermostat to fit all needs.

• 5/8” hose barb or 1” NPT threadconnections allow for easy in-lineinstallations on a variety of heatingunits.

• Weather resistant enclosure.

• Rated up to 480 volts.

Cord Type

Conduit Type6.43

3.66

3.34

3.78

3.10

1" NPT

1.93

1" NPT

14-3 HPN (4 FT.)2.57

4.16

5/8" Hosebarb

1.68

3.67

Conduit TypeModel Number

TypePlumbing Connections

Cord TypeModel Number

TFTCA-1NPTTFTCA-5/8HB

1” NPT X 1” NPT5/8” HB X 5/8” HB

TFTA-1NPTTFTA-5/8HB

Adjustable Range Electrical Rating

90°F to 130°F (Open or Off Setting)Differential 20°F (Close or On Setting)

120/240 Volt — 25 Amps277 Volt — 22Amps480 Volt — 12.5 Amps


Maximum Current Capacity:120V/208V/240V/277V — 25 Amps

380V/480V/575V — 15 AmpsTwo pole single throw.

To prevent overheating of the heatingelement on standby equipment andautomatic start engines, HOTSTARTrecommends turning the coolant heateroff when the engine is running. A pressureswitch that senses engine oil pressure isutilized to shut the heater off on increaseof oil pressure and to turn the heater onwhen engine oil pressure drops.

Oil Pressure Switches

For automatic cut-off of heaters when engine starts

Magnetic Contactors

Junction Boxes

Use to simplify wiring on equipment when a variety of heaters and controls are required.All models have ten, 25 Amp terminal blocks.

Inrush Voltamps (VA) 35 VA

Holding Voltamps (VA) 8 VA

Inrush Voltamps (VA) 92 VA

Holding Voltamps (VA) 10 VA

PDB-000

ControlComponents

PS252

MC330

3 PO

LE30

AM

PS

Kim HotstartModel Number

CoilVoltage

DRY LOCATIONS

MC330LMC330

120V240V

WET LOCATIONS

JBW11-000JBW12-000

120V240V

HAZARDOUS LOCATIONS

JBE11-000JBE12-000

120V240V

3 PO

LE60

AM

PS


CoilVoltage

DRY LOCATIONS

MC360LMC360

120V240V

WET LOCATIONS

JBW11-060JBW12-060

120V240V

HAZARDOUS LOCATIONS

JBE11-060JBE12-060

120V240V


EnclosureType

PS252

PS252R

PS252WT

PS252EP

Dry Locations

Dry Locations (Reverse Action)

Wet Locations

Hazardous Locations

PartNumber

Number ofOpenings

PDB-000 8*

* Box comes assembled with 4 strain relief connectors.For additional connectors, order part# PDB-1.

PDB-1

Complete Control Systems

All control boxes are available for Class 1 Group D hazardous locations, change prefix “JBW” to “JBE”. Consult factory for priceand availability.

Box Size Code: A – 6 x 6 x 4, B – 8 x 8 x 4, C – 10 x 8 x 4, D – 12 x 10 x 5

For heater protection and power savings HOTSTART recommends de-energizing the heater when engine is running. Onautomatic start engines this can be accomplished with a control system using an Oil Pressure Switch or a 24 Volt Relay.


Volts HOTSTART Model NumberMANUAL START ENGINES Amps HOTSTART Model Number

AUTOMATIC START ENGINES Volts

Single Ø — One Heater and Thermostat Per Engine120V208V240V277V

Use thermostat only.See pages 32 through 36.

25 Ampsor Less

Use oil pressure switch(PS252) & thermostat.

See pages 32-36 and page 37.

120V208V240V277V

Volts Manual Control Systems BoxSize

Automatic Control SystemsVoltsWith

24 Volt RelayBox Size

WithPressure Switch

Box Size

120V208V240V380V480V575V

JBW11-000JBW18-000JBW12-000JBW13-000JBW14-000JBW15-000

AAABBB

30 AmpsMaximum


BBBBBB


CCCCCC

120V208V240V380V480V575V

120V480V

JBW11-060JBW14-060

AB

60 AmpsMaximum

JBW11-160JBW14-160

BB

JBW11-260JBW14-260

CC

120V480V

Three Ø — One Heater and Thermostat Per Engine208V240V380V480V575V

JBW18-000JBW12-000JBW13-000JBW14-000JBW15-000

AABBB

30 Ampsor Less


BBBBB


CCCCC

208V240V380V480V575V

480V JBW14-060 B 60 AmpsMaximum JBW14-160 B JBW14-260 C 480V

Single Ø — Two Heaters and Two Thermostats Per Engine120V208V240V277V

Use one thermostat with each heater.See pages 32 through 36. 25 Amps

Per Heateror Less

Use one oil pressure switch (PS252) & thermostat with each heater.

See pages 32 through 36 and page 37.

120V208V240V277V

380V480V575V

JBW23-000JBW24-000JBW25-000

DDD

JBW23-100JBW24-100JBW25-100

DDD

JBW23-200JBW24-200JBW25-200

DDD

380V480V575V

120V208V240V380V480V575V


CCCDDD

30 AmpsPer HeaterMaximum


DDDDDD


DDDDDD

120V208V240V380V480V575V

Three Ø — Two Heaters and Two Thermostats Per Engine208V240V380V480V575V


CCDDD

30 AmpsPer Heater

or Less


DDDDD


DDDDD

208V240V380V480V575V

L1

L2

L3

Power In480V 3PH

Equipment Ground(must be grounded)

Equipment Ground(must be grounded)

H4 H1H2 H3

ControlTransformer

480V. PRI.

1A. Fuses

X1 X2120V. 50VA

1/2A. Fuse

Line Line

Load Load

PressureSwitch

ContactorCoil

ContactorCoil

C1

C2

2

2

4

5

Thermostat

Thermostat

3

3

MagneticContactors

C1 C1 C1 C2 C2 C2

E1 E2 E3 E4 E5 E6

10A. Fuses

HeatingElement

HeatingElement

3 Phase Only

L3

L1

Power In480V.

1 or 3Ø30 AMP

Transformer480V. PRI.

50VAH1 H3 H2 H4

1A. Fuses

X1

X1

X2120V Sec.

1/2A. Fuse

1

3 2C1

ContactorCoilThermostat

Control

MagneticContactor

L1 L2 L3

E1 E2 E3

C1 C1 C1

HeatingElement

39

All HOTSTART heaters with thermostats, designed to operate on 3-phase current (at anyvoltage), require the use of a control system with a 3-pole contactor. All Kim Hotstartheaters with thermostat designed to operate over 480 volt (1 phase or 3 phase) require acontrol system to reduce the primary voltage to 120 volts for the control circuit. Forincreased thermostat life, use a control system on all heaters above 277 volts either singleor three phase.

These control systems allow for quick electrical installation of all HOTSTART enginepreheaters. They are designed as a time and labor saving component. They are especiallyuseful on installations that require two coolant heaters or combinations of a coolantheater and oil heater/hydraulic heater etc.

All control boxes on this and preceding page are NEMA 12 & 13.

All control boxes are available for Class 1 Group D hazardous locations. Change prefix“JBW” to “JBE” and consult factory for price and availability.

Model JBW14-000No automatic control

Model JBW24-200With pressure switch

or

Model JBW24-100With 24 volt relay

To control one 480 volt heater at maximum 30 amps on manual start engine.

To control two 480 volt heaters at maximum 30 amps on automatic start engines.

TypicalControl BoxSystemComponents

Customer Support: (509) 536-8660 Toll-Free FAX: (800) 224-5550 www.hotstart.com

Prior 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.

MOUNTING

Mount 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.

DO 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.

DO 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.

The 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.

CAUTION

CAUTION

CAUTION

CAUTION

Technical Information & Heater Installation InstructionsOPERATING PRINCIPLE

The 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.

Note: 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 bank of 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.

VERTICAL MOUNTHORIZONTAL MOUNT

Outlet Neck

Outlet Neck

InletInlet

FIGURE 1

Lowest level of water jacket

YES NO

YES NO

1 2

YES

NO

NO

Coolant Flow


FIGURE 4

FIGURE 3

FIGURE 2

41

Section 5

Battery Pads

Battery Wraps

Silicone Hot Pads

Accessories For Multiple Battery Heating

Typical Connection - 2 Batterieson Each Side of Vehicle

100

80

60

40

20

0-20 0 +20 +40 +60 +80

Ambient Temperature, ˚F

Perc

ent

of B

atte

ry C

ran

kin

g P

ow

er

BatteryHeating Pads

A fully charged battery has only 40%cranking power at 0° F when comparedto 100% cranking power at 80° F.

Battery 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.

Standard Pad for Single Battery Special Pads for Multiple Batteries

B

A

Style C Style BStyle A

9.00REF TYP

9.00REF TYP

16-3 HPN

16-3 HPN

6" HPN

AA

BB

KB

7515

-D

KB

7515

-D

KB

7515

-D

KB

7515

-S

Left Side Battery Box Right Side Battery Box

BEC-6

BY-T68 BPC-61

Ground

2 FT4 FT6 FT8 FT

3 FT6 FT

16-3 HPN

15.375" 15.375"

15.375"

CORD, 16-3 HPN


ModelNumber Volts Watts Amps

NominalDimensions Batt.

Size Style A B

KB5015KB5015-SKB5015-D

120120120

505050

.42

.42

.42

8 1/4

8 1/4

8 1/4

131313

4D4D4D

ABC

KB7515KB7515-SKB7515-D

120120120

757575

.63

.63

.63

10 1/2

10 1/2

10 1/2

19 1/2

19 1/2

19 1/2

8D8D8D

ABC

KB7523KB7523-SKB7523-D

240240240

757575

.31

.31

.31

10 1/2

10 1/2

10 1/2

19 1/2

19 1/2

19 1/2

8D8D8D

ABC

EXTENSION CORDS

Model Length

BEC-2BEC-4BEC-6BEC-8

2’4’6’8’

POWER SUPPLY CORDS

Model Length Volts

BPC-31BPC-32BPC-61BPC-62

3’3’6’6’

120240120240

THERMOSTAT & “Y” CORD ASSEMBLY

ModelTemperature Control

On Off

BY-T68 60°F 80°F

Prolong the life of your battery with 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.

• Boosts battery cranking power as much as 75%.


Thermostat range: 65°F - 80°F

BatteryThermalWrap

Thermostatically 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.

BATTERY THERMAL WRAP — NO THERMOSTAT

Model Number Volts Watts Length

KBW5015-000 120 50 28”

KBW8015-000 120 80 36”

KBW16015-000 120 160 72”

BATTERY THERMAL WRAP — WITH THERMOSTAT

Model Number Volts Watts Length

KBW5015T-000KBW5024T-000

120240

5050

26”26”

KBW8015T-000KBW8024T-000

120240

8080

44”44”

KBW10015T-000KBW10024T-000

120240

100100

56”56”


Flexible, Versatile and Easy to Install.

HOTSTART adhesive pad heaters are ideal for oil pans, hydraulic reservoirs, engine blocks,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)

CAUTION: Do not use pads with higher than recommended wattage for specific oil capacities.

SiliconePad Heaters

Not for use on batteries

Model Number Dimensions Volts Watts

AF10015AF10024 4” x 5” 120

240100100

AF15015AF15024 4” x 5” 120

240150150

AF25015AF25024 5” x 6” 120

240250250

AF40015AF40024 6” x 8” 120

240400400

ApplicationGuidline

100 Watt 150 Watt 250 Watt 400 Watt

Engine oil pan 2 to 5 quarts 5 to 8 quarts 2 to 5 gallons 5 to 8 gallons

Diesel Tank 5 to 7 gallons 7 to 10 gallons 10 to 20 gallons 20 to 30 gallons

Hydraulic Tank 1 to 5 gallons 5 to 10 gallons 10 to 20 gallons 20 to 30 gallons

Water Tank up to 2 gallons 2 to 4 gallons 4 to 7 gallons 7 to 10 gallons

45

Section 6

In-block Heaters

Heater InstallationGuide

In-line Heater

Direct ImmersionCords

Thermocords

Flush Mount Kits

* If supplemental oil heating is desired, this column gives the correct thread size in oil pan. See NOTE on page 54.


Note: 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.

In-BlockDirect Immersion Heaters

Engine ModelPart Number

120 VoltsPart Number

240 Volts Watts Product Image Application InformationHeat Shield

RequiredOil Heater

Thread Size*

Allis Chalmers670T & I685T & I

6138LT, T & I25000 (844 CID)

AC-101CATV-151

AC-102CATV-152

10001500

Replaces 1” thread-in plug on the oil cooler atrear of the engine on the right side. Note that

not all of the engines have this opening.

Case/IH – Agricultural

ALL 4 CYL 390ALL 6 CYL 590

CUB-751FPCUB-101FPCUB-151FP


75010001500

Inserts in any of the freeze plugs right side ofengine 22mm

ALL 6 CYL 830 CUC-151FP CUC-152FP 1500 Inserts in the freeze plug right rear of theblock 22mm

CaterpillarC-10C-12

TF121-000 TF122-000 1250 Replaces the 1” threaded plug in the oil cooler bonnet YES 1” NPT

C-9 Non ACERTC-15 Non ACERTC-16 Non ACERT

CATV-151 CATV-152 1500C-9 Only: Mount in rear face of blockC-15, C-16: Mount in rear oil cooler bonnet

from the back end1” NPT

C7 ACERT3126

FP101-001FP151-001

FP102-001FP152-001

10001500

Replace 44mm frost plug on right hand sideof engine just below the turbo charger. YES

C7 ACERT rear port TL101-000 TL102-000 Replace 1-1/16” plug in the rear of the block

C9 ACERT CATV-151 CATV-152 1500 Replace 1” NPT plug in the right rear of theengine block

C11 ACERTC13 ACERT

TF151-008 TF152-008 1500 Replace any of the 1-5/16” plugs in rear of oilcooler on the right hand side of the engine

Check ExhaustRouting

1 5/16”STOR

C15 ACERTw/o breaksaver TF151-009 TF152-009 1500 Replace 1-3/16” plug in rear of the oil cooler

on the right hand side of the engine

C15 ACERTwith breaksaver TF151-008 TF152-008 1500 Replace 1-5/16” plug in the oil cooler on the

righ handside of engine

C9 2007 ACERTC13 2007 ACERTC15 2007 ACERT

TF151-012 TF152-012 1500 Replace 1-3/16” plug in the rear of the oilcooler on the right hand side of the engine

1674 CATB-151 CATB-152 1500 Replaces the 1-1/2” thread-in plug on the right side of the engine

1693 & D343 CATC-151 CATC-152 1500 Replaces water jacket access plate on the leftside of the engine

1693T & 1693TA CATC-151-S CATC-152-S 1500 Replaces water jacket access plate on the leftside of the engine

3013 1.5L3014 2.0L FP531-003 FP532-003 530 Replaces 40mm core plug on the front, left

side of the engine








RequiredOil Heater

Thread Size*

Caterpillar — Continued

3024 2.22L FP531-003 FP532-003 530 Replaces 40mm core plug on the front, leftside of the engine

3034 2.95L FP531-001 FP532-001 530 Replaces 50mm core plug located at back ofhead

3044 3.3L PF531-001 PF532-001 530Mounts in “football shaped” opening on the

right of the engine

3046 5.0L PF531-000 PF532-000 530 Replaces 35mm core plug located at rear ofengine, left side

3054 3.99L

3054B 4.23LPER-751FPPER-101FP

PER-752FPPER-102FP

7501000

Mounts in the 1-1/4” freeze plug opening onthe left side of the engine

3054C PER-751FP PER-752FP 750 Mounts in 1-1/4” freeze plug at left rear ofengine

3056 6.0L PER-151FP PER-152FP 1500 Mounts in the 1-1/2” freeze plug on the rightside of the engine

31143116

FP101-001FP151-001

FP102-001FP152-001

10001500

Replaces the core plug on the right side ofthe engine just below the turbocharger YES 11/16”X12

3176 10.3Lthrough 1995

DD8L-101CAT-12015TF151-001

DD8L-102CAT-12023TF152-001

100012501500

Replaces the 3/4” plug on the right side ofthe engine just below the head. 1” NPT

3176 10.3L1996 and later TF121-000 TF122-000 1250 Replaces the 1” threaded plug in the oil

cooler bonnet YES 11/16”X12

3196 12.0L TF121-000 TF122-000 1250 Replaces 1” threaded plug in oil cooler bonnet YES 11/16”X12

3204all 1100 series

CATX-751CATX-101

CATX-752CATX-102

7501000

Replaces the core plug on the right side of theengine just below the turbocharger 22mm

3208 — 2 heaters with a single cord CATX-2-751-Y CATX-2-752-Y 1500

total

Use on industrial engines when clearaccess is available.

Replaces any core plug - one on each sideof the engine

3208Recommended

AftermarketInstallation

JD3/4-101INJD1-101INJD3/4-151INJD1-151IN

JD3/4-102INJD1-102INJD3/4-152INJD1-152IN

1000100015001500

Replaces any of the 3/4” or 1” plugs on thewater transfer casting (right front of theengine). 3/4” use JD3/4 — 1” use JD1

3304

3306

DD8L-101CAT-12015TF151-001

DD8L-102CAT-12023TF152-001

100012501500

Replaces the 3/4” plug on the left side ofthe engine

3406C/E 14.6L AC-101CATV-151

AC-102CATV-152

10001500

Replaces 1” thread-in plug in the rear of the oilcooler bonnet on the right side of the engine 1” NPT








RequiredOil Heater

Thread Size*

Caterpillar — Continued

3406 & 3408except 1998

ADEM 2

AC-101CATV-151

AC-102CATV-152

10001500

Replaces 1” thread-in plug in the rear of the oilcooler bonnet on the right side of the engine 1” NPT

3406E1998 ADEM 2engines only

TF151-002 TF152-002 1500Replaces the 1” threaded plug that pointsdownward on the top of the rear of the oil

cooler bonnetYES 1” NPT

3406E ADEM 3 and ADEM

2000 engines

AC-101CATV-151

AC-102CATV-152

10001500

Replaces 1” thread-in plug in the rear of theoil cooler bonnet on the right side of the

engine1” NPT

3456 15.8L AC-101CATV-151

AC-102CATV-152

10001500

Replaces 1” thread-in plug in the rear of theoil cooler bonnet on the right side of the

engine 1” NPT

Chevrolet/GMC (Small Truck)

5.7L V8 (350 CID) FC601-501

NONE 600Mounts in the freeze plug in the engine’s

block

No replacement cord available6.2L V8 Diesel6.5L V8 Diesel FC601-PY2

Cummins6 Cylinder Engines: H, NT, NH, N Family

743 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 below

Group I

Flat plate design CUN-151B CUN-152B 1500 6 bolt flat plate on the right side of the

engine. May use either the forward or rearopening depending on clearance.

1” NPT

Flat plate design whenthe 1/2” NPT opening

is usedCUN-151BH CUN-152BH 1500 1” NPT

Group II

When an external oil cooler is used.. Note: 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/CNT152B90

When connection is 1 1/2” rubber hose

Engines produced Aug.1975 thru June 1982

CNT-151B-90 CNT-152B-90 15006 bolt, flat plate design with an elbow thatwill rotate 360 degrees to connect with any

hose or casting1” NPT

Uses an “O” ring forthe 1 1/4” water tube

connectionEngines producedprior to August ‘75

CNT-151B CNT-152B 1500 6 bolt, flat plate design with an elbow thatwill rotate 360 degrees to connect with any

hose or casting1” NPT








RequiredOil Heater

Thread Size*

Cummins — ContinuedGroup III

For industrial engineswith hole pattern

reversedCUN-151BREV CUN-152BREV 1500 Six bolt flat plate on the right side of the

block 1” NPT

Group IV

1998 and laterN14 Industrial PF151-002 PF152-002 1500 Six bolt flat plate on the right side of the

block 1” NPT

Additional Cummins Engine Models

Cummins A4 cyl & 6 cyl CUA-101F CUA-102F 1000 Inserts in any of the freeze plugs on right

side of engine. Element points down.

ISC/QSC 8.3LISL/QSL 9.0L DD8L-101 DD8L-102 1000 3/4” NPT threaded plug in the

right rear side of engine 22mm

L10, M11ISM CUL-151 CUL-152 1500 Inserts in the forward opening of the heater

casting on the right rear of block 1” NPT

QSB 3.9L, 5.9LISB 5.9 TF751-002 TF752-002 750 3/4” NPT threaded plug in the front

of the oil cooler casting 22mm

ISM/QSM 11.0LFlat Plate Design PF151-003 PF152-003 1500 Right rear. Replaces plate. 1” NPT

QSX, ISXSignature 600 PF151-004 PF152-004 1500 Mounts in the “football shaped” plate on the

right side of the block 27mm

4BT 3.9L CUB-751FPCUB-101FP

CUB-752FPCUB-102FP

7501000

Inserts in any of the freeze plugs right side of engine

Check ExhaustRouting 22mm

6BT 5.9LCUB-751FPCUB-101FPCUB-151FP


75010001500

Inserts in any of the freeze plugs right side of engine

Check ExhaustRouting 22mm

6CT 8.3L CUC-151FP CUC-152FP 1500 Inserts in the freeze plugright rear of the block 22mm

Detroit DieselSERIES 104 cylinder

Phaser engines

PER-751FPPER-101FP

PER-752FPPER-102FP

7501000

Mounts in the 1-1/4” freeze plug opening oneither side of the engine

SERIES 106 cylinder

Phaser enginesPER-151FP PER-152FP 1500 Mounts in the 1-1/2” freeze plug on the right

side of the engine

SERIES 30 DD8L-101 DD8L-102 1000 Mounts in the 3/4” NPT opening in the block








RequiredOil Heater

Thread Size*

Detroit Diesel – continued

SERIES 40all versions

PER-751FPINTA-121

FR151-001

PER-752FPINTA-122

FR152-001

75012501500

Mounts in the frost plug opening on the leftside of the engine

SERIES 50SERIES 60

AC-101CATV-151

AC-102CATV-152

10001500

Mounts in the 1” NPT opening in either waterpick up pipe (up to 1991) or in the 1” NPT

opening on the oil cooler housing after 1991

yes on 1991 andlater 3/4” NPT

SERIES 55 PF151-000 PF152-000 1500 Mounts in the triangle plate on the sideof the block

3-53, 4-53, 3-71, 4-71 with water

cooled air compressorDD-751-S DD-752-S 750 Mounts in the “football shaped” plate on

the block. Check clearance.

3-53, 4-53, 3-71, 4-71 without water

cooled air compressorDD-751 DD-752 750 Mounts in the “football shaped” plate on the

block. Check clearance.

6-71with water cooled air

compressorDD-151-S DD-152-S 1500 Mounts in the “football shaped” plate on the


6-71 without water cooled

air compressorDD-151 DD-152 1500 Mounts in the “football shaped” plate on the


8.2 L V-8 Diesel DD8L-101 DD8L-102 1000 Threads into the 3/4” NPT openingon the block

6V-53with water cooled air

compressorDD6V-751-S DD6V-752-S 750 Mounts in the “football shaped” plate on the


6V-53without water cooled

air compressorDD6V-751 DD6V-752 750 Mounts in the “football shaped” plate on the


6V71 & 8V71Alternate location

AC-101CATV-151

AC-102CATV-152

10001500

Threads into 1” NPT plug in the front face ofthe block

6V-71 & 8V-716V-92 & 8V-92

except GMC Generalmodels

DDV-151B DDV-152B 1500 Mounts in the square plate on the block

6V92 & 8V92alternate location -

threads into oil cooler.DD8L-101 DD8L-102 1000

Threads into the 3/4” NPT opening in the oilcooler housing.Note - not all engines have

this opening

DeutzBF4L913 BF6L913F3L912 F3L913

F6L913

1011 SERIESoil cooled engines

OLT221515 plusA22M48M(adapter)

n/a 150 Use adapter kit to mount the 22MM heater in the 48MM opening

22MMor

48MM








RequiredOil Heater

Thread Size*

Deutz – continued

1012 — 4 & 6 cyl1013 — 4 cyl PF751-000 PF752-000 750 Mounts in the “football shaped” plate

opening on the oil cooler casting

1013 6 cyl PF121-001 PF122-001 1250 Mounts in the “football shaped” plateopening on the oil cooler casting

10156 & 8 cyl TL151-004 TL152-004 1500 Mounts in 30MM plug in water elbow on

front of the engine

2012 — 4 & 6 cyl PF751-002 PF752-002 750 Mounts in the “football shaped” plateopening on the oil cooler casting

Ford

6.9L & 7.3L V-8diesels through 1993 FC101-PY1 None 1000 Mounts in a freeze plug on the engine's block.

No replacement cord available.

7.3L V-8 dieselsfrom 1994 on

TF751-002 DD8L-101

TF752-002 DD8L-102

7501000

Mounts in the 3/4” NPT plug in theengine's block

Hino

3.8L, 5.8L, 6.0L, 6.4L,6.7L, W04C-T, W06E,

H06C-T, H07C-BDD8L-101 DD8L-102 1000 Threads into 3/4” NPT opening

in the block YES

Isuzu

4BD1 6HE16BD1 6SA16BG1

TF401-501 NONE 400 Replaces 1” NPT plug in left rear of engine

Iveco

NEF 4cylNEF 6 cyl PF751-001 PF752-001 750 Mount in either front or rear opening on right

side of engine block

John Deere

With 3/4” plug in theback of the block

JD3/4-101INJD3/4-151IN

JD3/4-102INJD3/4-152IN

10001500

3/4” NPT opening in the rear face of the block

checkExhaust routing

With 1” plug in theback of the block

JD1-101INJD1-151IN

JD1-102INJD1-152IN

10001500

1” NPT opening in the rear face of the block

With 1 5/8” openingon the side of the

water jacketJDS-101 JDS-102 1000 1-5/8” threaded opening on the side of the

block in the water distribution channel








RequiredOil Heater

Thread Size*

John Deere – continued

6105 (10.5L)6125 (12.5L)

AC-101CATV-151

AC-102CATV-152

10001500 1” NPT opening in the oil cooler casting

Komatsu

L10 (10L)M11(11L) CUL-151 CUL-152 1500 Inserts in the forward opening of the heater

casting on the right rear of the block

SA6D125 MA-151 MA-152 1500 Threads into the freeze plug opening in the block

Kubota

M, B, L Series

D905 V1205D1005 V1305D1105 V1505D3000B V4000BD3200B V4300BDH905 VH1205DH1005 VH1305

TF401-501 N/A 400 Replaces 1” NPT plug in left front of engine

Mack

Mid liner E3MS200 & MS250 MAM-101 MAM-102 1000 Mounts in rear face of block

Mid liner E5MS300 MAM-151 MAM-152 1500 Mounts in the oil cooler bonnet

E6 engines“smooth bore”from 1981 on

MASB-151 MASB-152 1500 Mounts in the freeze plug opening. Smoothopening design.

E6 enginesthreaded freeze

plug openingnot produced after ‘81

END 465, 711,EN438, 504, 707,

673, 675, 676(1957 through 1981)

MA-151 MA-152 1500 Mounts in any threaded freeze plug opening

E7 Engines

Except E-Tech waterpump mount

PF151-001 PF152-001 1500Mounts in the plate in either the front or rearface of the block in the water jacket passage.For 2002 engine – mounts in rear face of block.

E9, ENDT865, 866 and 1000 series V8 engines

Use two heatersDD8L-101 DD8L-102 2000 total Threads into the 3/4” NPT opening on each

side of the block








RequiredOil Heater

Thread Size*

MAN

D2840D2842D2848

PF121-003 PF122-003 1250 Replace “football shaped” plate in lowerwater pipe on right side of engine

D2866D2876

PF151-006 PF152-006 1500Replace 3 bolt plate on left side of engine.

May require adapter if 3 bolt opening is notavailable on engine. Consult customer service.

Mercedes Benz

MBE904MBE906 PF101-001 PF102-001 1000 Replace frost plug in rear of engine on right

side YES

Massey Ferguson3 cylinder4 cylinder6 cylinder

PER-751FPPER-101FP

PER-752FPPER-102FP

7501000

Mounts in any of the 1-1/4” freeze plugopenings in the engine

Navistar/International

V800 (796 CID) AC-101CATV-151

AC-102CATV-152

10001500

Threads into a 1” NPT opening in the oil cooler bonnet

INLINE 6 CYLINDER— all series —

312, 360, 414, 436,466 & 530

PER-751FPINTA-121

FR151-001

PER-752FPINTA-122

FR152-001

75012501500

Mounts in the frost plug on the left sideof the engine.

Fits all series of these engines.

6.9L & 7.3LV8 diesels

through 1993

FC101-PY1or

FC601-501None

1000

600

No replacement cord available. Mounts in afreeze plug above starter

7.3L & T444all series DD8L-101 DD8L-102 1000 3/4” NPT threaded opening in the block

9.0L — V8 diesel INT9-101F INT9-102F 1000 Mounts in a freeze plug

Oliver

ALL EXCEPT 1265,1365 & 1900

TF751-002DD8L-101

TF752-002DD8L-102

7501000

Threads into a 3/4” NPT opening in the block

Onan — See Cummins “A” SeriesPerkins

3.1524.2366.354

PER-751FPPER-101FP

PER-752FPPER-102FP

7501000

Mounts in the 1-1/4” freeze plug opening onthe right side of the engine

103.15104.22404.22

FP531-003 FP532-003 530 Mounts in left front freeze plug





NOTE: The only replacement parts for the direct immersion heaters is the power cord. Please see the power cord section onpage 56 for the proper replacement cord set.

For thermostat control of in-block direct immersion heaters, see page 56. The energy saver Thermocord is available in varioustemperature ranges.

Supplemental heat for engines using in-block heaters can be achieved by the installation of oil pan heaters in the lube-oil.Reference pages 26 and 27 of this catalog or consult factory.




RequiredOil Heater

Thread Size*

Perkins – continued

700 Series704.30 FP531-001 FP532-001 530 Mounts in freeze plug in rear of head

800 Series PF531-001 PF532-001 530 Mounts in football shaped plate on the leftfront of the block

1004 (right side)FR751-002FR101-000PER-151FP

FR752-002FR102-000PER-152FP

75010001500

Mounts in the 1-1/2” freeze plug opening onthe right side of the engine

1004 (left side) PER-751FPPER-101FP

PER-752FPPER-102FP

7501000

Mounts in the 1-1/4” freeze plug opening onthe left side of the engine

1006 (6 Cyl) A & B PER-151FP PER-152FP 1500 Mounts in the 1-1/2” freeze plug on the rightside of the engine

1103C FR531-000 FR532-000 530Replaces 1-1/4” freeze plug on right rear of

engine. Element should pointtowards 1 O-clock position.

1104 (4 Cyl) C PER-751FPPER-101FP

PER-752FPPER-102FP

7501000

Mounts in 1-1/4” freeze plug opening on rightrear of engine with element straight up

in 12 O-clock position

Volvo

D9 PF151-007 PF152-007 1500 Mounts in the "football shaped" plate onthe front, right side of the engine

D12CPrior to Serial #

250502PF151-005 PF152-005 1500

Mounts below turbo charger on right centerof engine

YES

D12CAfter Serial # 250502 PF121-002 PF122-002 1250 YES

TD60, TD61, TD70,TD71, TD100, TD101,VE10, TD120, TD121

VT6-101 VT6-102 1000 Mounts into threaded opening (44mm) inthe front of the engine

Yanmar 3T72HLE4TN82E

D4TYYDXL4.41

TF401-501 N/A 4001” NPT

No replacement cord available


Instructions for:In-block direct immersion heaters

Please refer to specific instructions that accompany heater.

HeaterInstallation

THREADED PLUG TYPE HEATERS

PLATE TYPE HEATERS

FREEZE (CORE) PLUG TYPE HEATERS

Please follow these steps to ensure proper operation of your KimHotstart in-block heater.

1. Align cord with pins on the heater and press the cord intothe heater. Place clamp around cord & heater. DO NOT PLUGIN HEATER YET!

2. Route the cord, keeping away from hot or moving surfaces.

3. Re-fill the cooling system. Run engine until enginethermostat opens and continue running for another 20minutes to eliminate air.

4. Stop engine and let cool. Check for leaks. Check coolantlevel.

5. Plug heater into power supply and test for proper operation.Block should feel warm near heater.

A. Drain the coolingsystem.

B. Remove therecommended plug.(See instructions withheater)

C. Apply teflon tape topipe threads or greaseto O ring.

D. Thread heater intoengine.

A. Drain the coolingsystem.

B. Remove therecommended plate.(See instructions withheater)

C. Clean the gasket area.

D. Apply gasket sealant toplate and enginesurfaces.

E. Insert heater into engine.Tighten bolts.

Please follow these steps to ensure proper operation ofyour Kim Hotstart in-block heater.

1. Align cord with pins on the heater and press the cordinto the heater. Place clamp around cord & heater. DONOT PLUG IN HEATER YET!

2. Route the cord, keeping away from hot or movingsurfaces.

3. Re-fill the cooling system. Run engine until enginethermostat opens and continue running for another20 minutes to eliminate air.

4. Stop engine and let cool. Check for leaks. Checkcoolant level.

5. Plug heater into power supply and test for properoperation. Block should feel warm near heater.

A. Drain the cooling system.

B. Remove the recommended coreplug. (See instructions with heater)

C. Clean, smooth and dry core plugopening.

D. If retaining ring style, apply a lightcoat of grease to the O ring and coreplug opening. If press-in style, applya light coat of high-temperature,high-strength retaining compound(Loctite 640 recommended).

E. Insert heater into engine andposition properly. Push the heaterinto the engine by hand, then tap inusing a suitable tool until flange iseven with engine block.

Please follow these steps to ensure properoperation of your Kim Hotstart in-block heater.

1. Align cord with pins on the heater and pressthe cord into the heater. Place clamp aroundcord & heater. DO NOT PLUG IN HEATER YET!

2. Route the cord, keeping away from hot ormoving surfaces.

3. Re-fill the cooling system. Run engine untilengine thermostat opens and continuerunning for another 20 minutes to eliminateair.

4. Stop engine and let cool. Check for leaks.Check coolant level.

5. Plug heater into power supply and test forproper operation. Block should feel warmnear heater.


Thermocord for In-Block Direct Immersion heaters

Thread TempPart No. Volts Size Range

A-2822-ØB 120 1/2" 100-120

A-2822-ØC 120 1/2" 120-140

A-2822-ØH 240 1/2" 100-120

A-2822-ØI 240 1/2" 120-140

A-2822-ØM 120 1/2" 80-100

A-2822-ØP 240 1/2" 80-100

4 ft.

3 ft.

3 ft.

NOTE: When orderingin-block heater and

thermocord, place suffix–WOC (which stands for

without cord) after theheater model number tosave cost as the standard

6 foot heater cord isreplaced by the

thermocord harness.

Heater shown for illustration purposes only.

ENERGY

SAVER

Heat Shield

ModelNo.

HS1

Use when exhaust manifold orturbo come close to heater

termination.

For use with In-Block Direct Immersion heaters

CordLength

PlugStyle

120 Volt 240 Volt

6’ 1 IM6-1IN IM6-2IN

11’ 1 IM11-1IN IM11-2IN

16’ 1 IM16-1IN IM16-2IN

CordLength

PlugStyle

120 Volt 240 Volt

6’ 2 11PR72T 21PR72T

11’ 2 11PR132T 21PR132T

16’ 2 11PR192T 21PR192T

STYLE 1

STYLE 2

Fits most competitor's applications.

ReplacementCords &

Thermocords

11PR72T

IM6-1IN


Other Accessories

FlushMount Kits&Accessories

Flush mount kits for tank heatersModel

NumberVolts Amps

For Heater withWattage of: Kits include:

Recessed malereceptacle with 6’ cord

(no female connectors),hinged flip cover and

female connector

FM15120 120 15 500 to 1800

FM15240 240 15 500 to 3000

FM20120 120 20 2000 to 2250

3.5.78125

.3125

Recessed Male Receptacle – with 6 ft. cord (no female connectors)Model Number Volts Amps

RM5-15RM6-15RM5-2ØRM6-2Ø

120240120240

15152020

Female Connector Only - for extension cordsModel Number Volts Amps

FM1G2ØAFM2G2ØA

120240

15/2015/20

Hinged Cover Only

Model Number Description3.25 .78125

3.3125*FC-KHFC-KH-C

Black/Kim LogoChrome/Kim Logo

*Note: Standard with kit

Plug HousingModel Number

A-2223-PH

Flush mount kits for In-Block Direct Immersion heatersModel Number

120 VoltModel Number

240 VoltCord

LengthPlugStyle Kits include:

11PR- style cord(shown on page 56),

recessed malereceptacle and hinged

flip cover

IM6-1IN-FM IM6-2IN-FM 6’ 2



3.5.78125

.3125


-40° F -40° C-30° F -34° C-20° F -29° C-10° F -23° C

0° F -18° C10° F -12° C20° F - 7° C30° F - 1° C40°F 4.5°C50°F 10.0°C60°F 15.5°C70°F 21.0°C80°F 26.5°C90°F 32.0°C

100°F 37.5°C110°F 43.5°C120°F 49.0°C130°F 54.5°C140°F 60.0°C150°F 65.5°C160°F 71.0°C170°F 76.5°C180°F 82.0°C190°F 88.0°C200°F 93.5°C210°F 99.0°C

Cubic Inches Litres Cubic Inches Litres Cubic Inches Litres150 2.46 1600 26.22 3050 49.98200 3.28 1650 27.04 3100 50.80250 4.10 1700 27.86 3150 51.62300 4.92 1750 28.68 3200 52.44350 5.74 1800 29.50 3250 53.26400 6.55 1850 30.32 3300 54.08450 7.37 1900 31.13 3350 54.90500 8.19 1950 31.95 3400 55.71550 9.01 2000 32.77 3450 56.53600 9.83 2050 33.59 3500 57.35650 10.65 2100 34.41 3550 58.17700 11.47 2150 35.23 3600 58.99750 12.29 2200 36.05 3650 59.81800 13.11 2250 36.87 3700 60.63850 13.93 2300 37.69 3750 61.45900 14.75 2350 38.51 3800 62.27950 15.57 2400 39.33 3850 63.09

1000 16.39 2450 40.15 3900 63.911050 17.21 2500 40.97 3950 64.731100 18.03 2550 41.79 4000 65.551150 18.84 2600 42.61 4050 66.371200 19.66 2650 43.42 4100 67.191250 20.48 2700 44.24 4150 68.001300 21.30 2750 45.06 4200 68.821350 22.12 2800 45.88 4250 69.641400 22.94 2850 46.70 4300 70.461450 23.76 2900 47.52 4350 71.281500 24.58 2950 48.34 4400 72.101550 25.40 3000 49.16 4450 72.92

Cubic Inches x 0.01639 = Liters

Liters x 61.024 = Cubic Inches

Conversion ChartFahrenheit - Celsius

F = C x 9/5 + 32C = (F - 32) x 5/9

Cubic Inches - Litres Conversion Chart

1. Determine the best type of heater to be used for the application.• Direct Immersion or Tank Type?• Weathertight unit for all indoor or outdoor applications (hospital, communications

building, shopping mall, pump station, off-road equipment).• Explosion Proof unit for Hazardous Locations (off-shore platform,

oil rig, gas compression station).

2. Determine engine size.• Cubic inch or litre displacement.

3. Determine wattage required by using this general formula:• 3 watts x cubic inch displacement = watts required.Example: Engine is 855 C.I.D. — 855 x 3 = 2565. Requirement is 2500 watt heater.• This formula is a very good rule of thumb to use down to 0°F ambient

temperature. This formula will generally hold engine temperature at approximately 100°F above ambient.

• Very large engines may require a forced circulation system (see pages 16, 17 and 59).

4. Now that you have the required wattage, you need to determine:• Voltage available that will power the heater (120, 208, 277, 240, 380, 480).• Is the power source Single Phase or Three Phase?

5. For thermostat selection, determine the desired engine temperature to be maintained.• 100°F to 120°F applies 95% of the time. However, specifications vary with respect

to the user and a higher or lower range may be required.

You now have the specifications needed to select the required engine pre-heaterfrom the many products listed in this catalog. For other technical information andinstallation tips, see pages 40 and 55. If you have other questions or need additionalassistance, please contact our customer service department.

Conversion Factors

Litres x 1.0567 = QuartsQuarts x 0.94635 = LitresLitres x 0.26417 = GallonsGallons x 3.7854 = Litres

Specifyingan Engine

Pre-Heater


HOTSTART offers complete circulating heating systems for any large industrial engine.These systems are engineered and designed specifically for installation on a largegenerator, compressor package, marine engine, or locomotive. Most systems are mountedon a steel plate with a pre-wired junction box, pump and motor components, a flowdetection device and in-line high-limit thermostats. Plus, most systems have fused 120volt control voltage, regardless of applied voltage.

Several systems are available for lube oil heating, coolant heating, diesel fuel heating orcombinations of any aforementioned fluid. Systems are adaptable to function inwet/damp locations or hazardous environments. Complete with all necessary componentsand controls, these automated systems are available in various wattage, voltage andphase combinations to accommodate most large industrial preheating needs.

For additional information regarding HOTSTART’s circulating heating systems, pleasecontact HOTSTART and have all your questions answered by one of our engine heatingproduct specialists.

COR Modelfor locomotive engines

coolant/lube oil combinationheating system

Large capacity systems heatand circulate coolant or lubeoil to efficiently maintain anengine’s optimumtemperature during shut-down and layover periods.

CL ModelCoolant only, watertight

circulating heating system

OER ModelOil only, Class I Group D


Circulating-type combinationheating systems combine thebenefits of coolant heatingand oil heating into one pre-wired, pre-assembled dualheating system.

COLER ModelClass I Group D combination


COL ModelWatertight with NEMA 12 enclosures

combination circulating heating system

Lloyds & ABS Approved

IndustrialCirculatingSystems -Largeengineapplications

All HOTSTART circulatingheating systems come pre-wired and pre-assembled foreasy installation, operation andmaintenance.

60

Customer Services

To better serve you, HOTSTARTprovides a customer servicedepartment to answer all yourengine heating concerns, anyquestions regarding HOTSTARTproducts or to take your sales order.

Customer Support Department: (509) 536-8660

Sales orders and requests for quotescan also be faxed in over our toll-freeFAX line.

Toll-free FAX line: (800) 224-5550

Warranty Information

The warranty below has been drafted to comply with the Federal Law applicable toproducts manufactured after December 31, 1976. This warranty gives you specific legalrights, and you may also have other rights which vary from state to state.

HOTSTART products are warranted against defects in workmanship and materials. Noother express warranty, written or oral, applies. No person is authorized to give any otherwarranty or assume any liability except by written statement from an officer of HOTSTARTInc.

The warranty extends for twelve months from date of shipment from factory orauthorized distributor.

Products must be installed and maintained in accordance with HOTSTART Inc.instructions. Users are responsible for the suitability of the products to their application.There is no warranty against damage resulting from corrosion, misapplication, improperspecification or other operating conditions beyond our control. Claims against carriers fordamage in transit must be filed by the buyer.

Absolutely no material can be returned to HOTSTART Inc. without prior factoryauthorization.

Upon factory authorization, return the defective part or product , freight prepaid, to:HOTSTART Inc., 5723 E. Alki, Spokane Valley, WA 99212. Telephone (509) 534-6171; FAX(509) 534-4216.

Defective items will be repaired or replaced, at our option, at no charge. Such repair orreplacements is the exclusive right of HOTSTART Inc. HOTSTART Inc. is not liable for laborcosts incurred in removal, reinstallation, or unauthorized repair of the product or fordamage of any type whatsoever including incidental or consequential damage. Somestates do not allow the exclusion or limitation of incidental or consequential damages, sothe preceding limitation or exclusion may not apply to you.

HOTSTART Inc.

P.O. Box 11245Spokane Valley, Washington U.S.A 99211-0245

Phone: (509) 534-6171Fax: (509) 534-4216

Toll Free Fax: (800) 224-5550www.hotstart.com

Distributor

12-09

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Catalog Hotstart IMC-600

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