Imc 700 10 16

IMC-700
PRODUCT CATALOG
E N G IN E H E ATE R S • OIL HEAT ERS • C ONT RO LS • AC C ESS OR I E S
TABLE OF CONTENTS
HEATER INSTALLATION PAGES 4 - 5

• Page 22 (Thermosiphon) 1 • HOTflow ® Engine Heaters
CTM, CSM Models
• Page 51 (In-block)
PAGES 6 - 17
• Thermosiphon Engine Heaters
Weathertight Design
HOW TO SPECIFY AN TPS, CB, CL, WL, SB, SL Models
ENGINE HEATER
PAGES 18 - 21
• Page 54 • Thermosiphon Engine Heaters
Hazardous Location
EE Models
CONVERSION CHARTS
PAGES 24 - 29
• Page 54
2 • Lube Oil Heaters (AC and DC)
• Industrial Immersion Heaters
Thread-in and Threadless Models
PAGES 31 - 36
CUSTOM PRODUCTS 3 • Remote Thermostats for Lube Oil Heaters
• Temperature Controls for Thermosiphon Engine Heaters
Call for information on: • Complete Control Systems
• Wiring Harnesses PAGES 38 - 40

• APUs
• Forced Circulation Heating
4 • Battery Warming Pads & Accessories
• Blanket Style Battery Warmers
• Silicone Hot Pads
Systems
PAGES 42 - 53
• Other Specialty Products
5 •
•
•
In-block Heaters
Electrical Cords for In-block Heaters
Thermocords
• Flush Mount Kits and Accessories
SECTION 1
HOTflow ® and THERMOSIPHON ENGINE HEATERS

HOTflow ® Engine Size Power Supply
Model Number kW Amps
Thermostat Range
CID/Liter Volts Ø Hz On Off
Engine Heaters
CTM w/8’ (2.4 m) cord and NEMA plug*
CTM Model
0 – 500 CID 120 1 60 CTM10110-N00 1 8.8 100 °F (38 °C) 120 °F (49 °C)
Single Phase 0-8 L 240 1 50/60 CTM10210-N00 1 4.4 100 °F (38 °C) 120 °F (49 °C)
500 – 750 CID 120 1 60 CTM15110-N00 1.5 13.0 100 °F (38 °C) 120 °F (49 °C)
1000–2500 Watts 8 - 12 L 240 1 50/60 CTM15210-N00 1.5 6.5 100 °F (38 °C) 120 °F (49 °C)
750 – 1200 CID 120 1 60 CTM25110-N00 2.5 21.3 100 °F (38 °C) 120 °F (49 °C)
12 – 20 L 240 1 50/60 CTM25210-N00 2.5 10.7 100 °F (38 °C) 120 °F (49 °C)
Meets requirements for CTM w/9.8’ (3 m) cord, without plug
installation on any
UL 2200 listed generator. 0 – 500 CID 120 1 60 CTM10110-A00 1 8.8 100 °F (38 °C) 120 °F (49 °C)
0–8L 240 1 50/60 CTM10210-A00 1 4.4 100 °F (38 °C) 120 °F (49 °C)
500 – 750 CID 120 1 60 CTM15110-A00 1.5 13.0 100 °F (38 °C) 120 °F (49 °C)
8 – 12 L 240 1 50/60 CTM15210-A00 1.5 6.5 100 °F (38 °C) 120 °F (49 °C)
750 – 1200 CID 120 1 60 CTM25110-A00 2.5 21.3 100 °F (38 °C) 120 °F (49 °C)
12 – 20 L 240 1 50/60 CTM25210-A00 2.5 10.7 100 °F (38 °C) 120 °F (49 °C)
CTM w/9.8’ (3 m) cord and Schuko plug (Euro)**
0 – 500 CID
240 1 50/60 CTM10210-E00 1 4.4 100 °F (38 °C) 120 °F (49 °C)
0–8L
Isolation Mounting 500 – 750 CID

240 1 50/60 CTM15210-E00 1.5 6.5 100 °F (38 °C) 120 °F (49 °C)
8 – 12 L
Kit (optional) 750 – 1200 CID
240 1 50/60 CTM25210-E00 2.5 10.7 100 °F (38 °C) 120 °F (49 °C)
CTM-IMK 12 – 20 L
* - UL/C-US listed Other voltages available. Consult the factory.

** - CE compliant
HOTSTART’s HOTflow ®
engine heater (CTM Model)
1
features an integrated pump W
that combines the benefits
of forced circulation with
a compact design that can H 2
mount to a variety of small
W
engine applications. Forced
circulation of the coolant
delivers uniform heating
throughout the entire engine,
extends element life and
Height (H) Width1 (W1) Width2 (W2) Weight
offers a significant reduction in
9.1” 7.0” 6.3” 3.5 lbs.
electrical consumption.
230 mm 145 mm 161 mm 1.6 kg
4 Customer Service: 509.536.8660 hotstart.com

Engine Size Power Supply
Model Number kW Amps Style
Thermostat Range HOTflow ®
CID/Liter Volts Ø Hz On Off
Engine Heaters
120 1 60 CSM10301-000 3 26.3 A
100 °F (38 °C) 120 °F (49 °C) CSM Model
208 1 60 CSM10308-000 3 15.1 A
100 °F (38 °C) 120 °F (49 °C)
208 3 60 CSM30308-000 3 8.7 B Single & Three Phase
1000 – 2000 CID 100 °F (38 °C) 120 °F (49 °C)
230 1 50 * CSM1030J-5A0 3 13.7 A
100 °F (38 °C) 120 °F (49 °C)
15 – 30 L 240 1 60 CSM10302-000 3 13.1 A
100 °F (38 °C) 120 °F (49 °C)
400 3 50 * CSM3030A-5A0 3 4.9 B 3000–12000 Watts
100 °F (38 °C) 120 °F (49 °C)
480 1 60 CSM10304-000 3 7.0 B
100 °F (38 °C) 120 °F (49 °C)
480 3 60 CSM30304-000 3 4.4 B
208 1 60 CSM10608-000 6 29.6 A 100 °F (38 °C) 120 °F (49 °C)
208 3 60 CSM30608-000 6 17.1 B 100 °F (38 °C) 120 °F (49 °C)
230 1 50 * CSM1060J-5A0 6 26.7 A 100 °F (38 °C) 120 °F (49 °C) Meets requirements for
2000 – 3000 CID 240 1 60 CSM10602-000 6 25.6 A 100 °F (38 °C) 120 °F (49 °C) installation on any UL 2200
400 3 50 * CSM3060A-5A0 6 8.9 B 100 °F (38 °C) 120 °F (49 °C) listed generator.
25 – 50 L 440 3 60 * CSM3060F-5A1 6 8.1 B 100 °F (38 °C) 120 °F (49 °C)
480 1 60 CSM10604-000 6 12.8 B 100 °F (38 °C) 120 °F (49 °C)
480 3 60 CSM30604-000 6 7.4 B 100 °F (38 °C) 120 °F (49 °C) HOTSTART’s HOTflow ®
575 3 60 CSM30605-000 6 6.2 B 100 °F (38 °C) 120 °F (49 °C)
engine heater (CSM Model)
208 1 60 CSM10908-000 9 44.0 A 100 °F (38 °C) 120 °F (49 °C)
208 3 60 CSM30908-000 9 25.4 B 100 °F (38 °C) 120 °F (49 °C) features a thermostat, pump
230 1 50 * CSM1090J-5A0 9 39.8 A 100 °F (38 °C) 120 °F (49 °C) and all required controls.
3000 – 4500 CID 240 1 60 CSM10902-000 9 38.1 A 100 °F (38 °C) 120 °F (49 °C)
400 3 50 * CSM3090A-5A0 9 13.2 B 100 °F (38 °C) 120 °F (49 °C)
Forced circulation of the
50 – 75 L 440 3 60 * CSM3090F-5A1 9 12.2 B 100 °F (38 °C) 120 °F (49 °C) coolant delivers uniform
480 1 60 CSM10904-000 9 19.1 B 100 °F (38 °C) 120 °F (49 °C) heating throughout the
480 3 60 CSM30904-000 9 11.0 B 100 °F (38 °C) 120 °F (49 °C)
575 3 60 CSM30905-000 9 9.2 B 100 °F (38 °C) 120 °F (49 °C) entire engine, extends
208 1 60 CSM11058-000 10.5 51.2 B 100 °F (38 °C) 120 °F (49 °C) element life and offers a
208 3 60 CSM31208-000 12 33.7 B 100 °F (38 °C) 120 °F (49 °C) significant reduction in
230 1 50 * CSM1120J-5A0 12 52.8 B 100 °F (38 °C) 120 °F (49 °C)
240 1 60 CSM11202-000 12 50.6 B 100 °F (38 °C) 120 °F (49 °C) electrical consumption.
4500 – 6000 CID
400 3 50 * CSM3120A-5A0 12 17.5 B 100 °F (38 °C) 120 °F (49 °C)
75 – 100 L 440 3 60 * CSM3120F-5A0 12 15.9 B 100 °F (38 °C) 120 °F (49 °C)
The HOTflow ® CSM
480 1 60 CSM11204-000 12 25.3 B 100 °F (38 °C) 120 °F (49 °C)
480 3 60 CSM31204-000 12 14.6 B 100 °F (38 °C) 120 °F (49 °C) operates automatically
575 3 60 CSM31205-000 12 12.2 B 100 °F (38 °C) 120 °F (49 °C) when provided contacts are
* CE compliant/union pump configuration supplied with a 24 V DC
Other voltages available. Consult the factory.
signal from the engine.
* union pump
* union pump
Style A
Style B
H
H
D W D
W
Height (H) Width (W) Depth (D) Weight Height (H) Width (W) Depth (D) Weight
15.0” 19.4” 9.5” 37 lbs. 17.0” 19.4” 9.5” 54 lbs.
383 mm 493 mm 242 mm 16.8 kg 434 mm 493 mm 242 mm 24.5 kg
* If a union pump is installed, the model’s height (H) will decrease by approximately 1.5” (38 mm)
Customer Service: 509.536.8660 hotstart.com 5

Thermosiphon Engine
Watts
Model Number
Amps
Model Number
Amps
Model Number
Amps
Displacement 120V 240V 277V
Engine Heaters
TPS051GT8-000 4.2 TPS052GT8-000 2.1
TPS Model 150 CID TPS051GT10-000 4.2 TPS052GT10-000 2.1
500 TPS057GT10-000 1.8
Single Phase 2.5 L TPS051GT12-000 4.2 TPS052GT10-013 2.1
— — TPS052GT12-000 2.1
500–2000 Watts TPS101GT8-000 8.4 TPS102GT8-000 4.2

350 CID TPS101GT10-000 8.4 TPS102GT10-000 4.2
1000 TPS107GT10-000 3.6
5.7 L TPS101GT12-000 8.4 TPS102GT10-013 4.2
— — TPS102GT12-000 4.2
TPS151GT8-000 12.5 TPS152GT8-000 6.3

350 – 500 CID TPS151GT10-000 12.5 TPS152GT10-000 6.3
1500 TPS157GT10-000 5.4
5.7 – 8.2 L TPS151GT12-000 12.5 TPS152GT10-013 6.3
— — TPS152GT12-000 6.3
TPS181GT8-000 15
1800 TPS181GT10-000 15 — — — —
TPS181GT12-000 15
500 – 700 CID
TPS202GT8-000 8.3
8.2 – 11.5 L
TPS202GT10-000 8.3
2000 — — TPS207GT10-000 7.2
TPS202GT10-013 8.3
TPS202GT12-000 8.3
Temperature Range Numerical
ON OFF Code
Power cord length on all models – 48” (1219 mm)
80 °F (27 °C) 100 °F (38 °C) 8 TPS engine preheaters include a fixed setting thermostat. A single or double digit numeral at the end of the model
100 °F (38 °C) 120 °F (49 °C) 10 number prefix designates the temperature range. Example: TPS101GT10-000 (see chart in left column)
120 °F (49 °C) 140 °F (60 °C) 12
-013 Engine preheater features 2 meter round cord and Shucko plug - CE compliant
Replacement Parts Model

Replacement Parts
Number Sensing Power Element

Element Tank Box
For TPS Models Unit Cord O-ring
TPS051GT8-000 LSU-8 REPS051T8 TPS-T CPS-1 11P48UU TPS-BOR
Replacement TPS052GT8-000 LSU-8 REPS052T8 TPS-T CPS-1 21P48UU TPS-BOR
Tank
TPS052GT10-013 LSU-10 REPS052T10 TPS-T CPS-2 21SCH81UU TPS-BOR
TPS057GT10-000 LSU-10 REPS057T10 TPS-T CPS-1 16H48UU TPS-BOR
Element
O-Ring TPS101GT12-000 LSU-12 REPS101T12 TPS-T CPS-1 11P48UU TPS-BOR
Replacement
Element TPS102GT10-000 LSU-10 REPS102T10 TPS-T CPS-1 21P48UU TPS-BOR
Sensing Unit TPS151GT8-000 LSU-8 REPS151T8 TPS-T CPS-1 11P48UU TPS-BOR

Replacement
Cord TPS157GT10-000 LSU-10 REPS157T10 TPS-T CPS-1 16H48UU TPS-BOR
TPS181GT8-000 LSU-8 REPS181T8 TPS-T CPS-1 12P16H48UU TPS-BOR
Replacement TPS181GT10-000 LSU-10 REPS181T10 TPS-T CPS-1 12P16H48UU TPS-BOR
Box TPS181GT12-000 LSU-12 REPS181T12 TPS-T CPS-1 12P16H48UU TPS-BOR

Engine
Displacement
Model Number Volts Watts Phase Amps
Thermostat Range
Thermosiphon
On Off
TPS051GT12-001 120 500 1 4.2 100 °F (38 °C) 120 °F (49 °C)
Engine Heaters
150 CID TPS051GT12-A00 120 500 1 4.2 ADJUSTABLE
TPS052GT12-001 240 500 1 2.1 100 °F (38 °C) 120 °F (49 °C) TPS Model w/in-line
2.5 L
TPS052GT12-A00 240 500 1 2.1 ADJUSTABLE adjustable and
TPS101GT12-001 120 1000 1 8.4 100 °F (38 °C) 120 °F (49 °C)
remote thread-in
350 CID TPS101GT12-A00 120 1000 1 8.4 ADJUSTABLE fixed thermostat.
5.7 L TPS102GT12-001 240 1000 1 4.2 100 °F (38 °C) 120 °F (49 °C)
TPS102GT12-A00 240 1000 1 4.2 ADJUSTABLE
Single Phase
TPS151GT12-001 120 1500 1 12.5 100 °F (38 °C) 120 °F (49 °C)
350 – 500 CID TPS151GT12-A00 120 1500 1 12.5 ADJUSTABLE
500–2000 Watts
5.7 – 8.2 L TPS152GT12-001 240 1500 1 6.3 100 °F (38 °C) 120 °F (49 °C)
TPS152GT12-A00 240 1500 1 6.3 ADJUSTABLE
TPS181GT12-001 120 1800 1 15 100 °F (38 °C) 120 °F (49 °C)

500 – 700 CID TPS181GT12-A00 120 1800 1 15 ADJUSTABLE
8.2 – 11.5 L TPS202GT12-001 240 2000 1 8.3 100 °F (38 °C) 120 °F (49 °C)
TPS202GT12-A00 240 2000 1 8.3 ADJUSTABLE Remote Adjustable
Thermostat Assembly
-001 Remote thread-in fixed temperature thermostat Adjustable 90 ° – 130 °F (32 ° – 54 °C)
On differential -20 °F (-7 °C) Part Number TFTA-5/8HB
In-line thermostat options:

OUTLET HOSEBARB 0.625 I.D.
Power Y-cord 1.5”
0.25” (4X) Holes 38mm
For Mounting
Brackets
Adjustable
Thermostat 6.7”
Assembly 7.9” 170mm
201mm 4.25”
108mm
Thermostat
Well
4.6”
In-Line INLET 117mm
Adjustable HOSEBARB
Thermostat 0.625 I.D.
Remote Thread-in
Fixed Temperature Thermostat
Replacement Parts Replacement Parts

Model
Volts Watts
Number Sensing
Element
Power Thermostat For TPS Model
Unit Y-cord Well
w/in-line adjustable
TPS051GT12-001 120 500 LSU-10 REPS051T12 TPS-YC1 TW2374-1 and remote thread-in
TPS051GT12-A00 120 500 RSU90-130 REPS051T12 # #
TPS052GT12-001 240 500 LSU-10 REPS052T12 TPS-YC2 TW2374-1
fixed thermostat.
TPS052GT12-A00 240 500 RSU90-130 REPS052T12 # #

Single Phase
TPS101GT12-A00 120 1000 RSU90-130 REPS101T12 # #
TPS102GT12-001 240 1000 LSU-10 REPS102T12 TPS-YC2 TW2374-1 Common replacement parts
TPS102GT12-A00 240 1000 RSU90-130 REPS102T12 # #
for all TPS engine preheaters:
TPS151GT12-001 120 1500 LSU-10 REPS151T12 TPS-YC1 TW2374-1 — Tank
TPS151GT12-A00 120 1500 RSU90-130 REPS151T12 # #
— Box
TPS152GT12-A00 240 1500 RSU90-130 REPS152T12 # # — Element O-ring
TPS181GT12-001 120 1800 LSU-10 REPS181T12 12P16H54S54X10UU TW2374-1

TPS181GT12-A00 120 1800 RSU90-130 REPS181T12 # #
See table on page 6
TPS202GT12-A00 240 2000 RSU90-130 REPS202T12 # #
-001 Remote thread-in fixed temperature thermostat # Call Factory

Thermosiphon Engine Model Number
Model Number
with Thermostat Volts Watts Phase Amps
Displacement without Thermostat
Engine Heaters see chart 1
CB115100-000 CB1151XX-200 120 1500 1 12.5

CB Model CB115800-000 CB1158XX-200 208 1500 1 7.2
Weathertight 350 – 500 CID CB115200-000 CB1152XX-200 240 1500 1 6.3
Single Phase 5.7 – 8.2L CB115700-000 CB1157XX-200 277 1500 1 5.4
CB115300-000 CB1153XX-200 380 1500 1 3.9
CB115400-000 CB1154XX-200 480 1500 1 3.1
1500–2500 Watts
CB120100-000 CB1201XX-200 120 2000 1 16.7

500 – 600 CID CB120800-000 CB1208XX-200 208 2000 1 9.6
CB120200-000 CB1202XX-200 240 2000 1 8.3
8.2 – 9.8L CB120300-000 CB1203XX-200 380 2000 1 5.3
CB120400-000 CB1204XX-200 480 2000 1 4.2
CB125100-000 CB1251XX-200 120 2500 1 20.8

CB125800-000 CB1258XX-200 208 2500 1 12.0
600 – 800 CID CB125200-000 CB1252XX-200 240 2500 1 10.4
9.8 – 13.1L CB125700-000 CB1257XX-200 277 2500 1 9.0
CB125300-000 CB1253XX-200 380 2500 1 6.6
CB125400-000 CB1254XX-200 480 2500 1 5.2
CB Model without thermostat
CHART 1
Heaters with Thermostats Temperature Range Numerical

To specify temperature range of ON OFF Code
thermostat, insert numerical code
from chart in place of the XX in 80 °F (27 °C) 100 °F (38 °C) 08
model number. 100 °F (38 °C) 120 °F (49 °C) 10
Example: 120 °F (49 °C) 140 °F (60 °C) 12
CB Model with thermostat Desired Temp. Range: 100 ° – 120 °F
Model Number: CB1151XX-200 Adjustable 90 ° – 130 °F
Order as: CB115110-200 A3
(32 ° – 54 °C)
CB Model
16.2” 4.1”
411mm 104mm
OUTLET, 1” NPT
5.75” FEMALE
146mm
4.3”
109mm
INLET, 1” NPT
FEMALE
20.1” 5.1”
510mm 129mm
OUTLET, 1” NPT
5.75” FEMALE
146mm
5.2”
132mm
INLET, 1” NPT
FEMALE

Model Number Model Number
with Element Common Replacement Parts
without
Thermostat Replacement available for all listed heaters Replacement Parts
Thermostat see chart 2
High Limit
CB115100-000 CB1151XX-200 RECB1151
Control
HLC-165 For thermosiphon
CB115800-000 CB1158XX-200 RECB1158
CB115200-000 CB1152XX-200 RECB1152 engine heaters
Check Valve RV-M
CB115700-000 CB1157XX-200 RECB1157 CB Model
CB115300-000 CB1153XX-200 RECB1153
CB115400-000 CB1154XX-200 RECB1154 Element O-ring TMM-OR
Tank RTB CHART 2

CB120100-000 CB1201XX-200 RECB1201
CB120800-000 CB1208XX-200 RECB1208 Heaters with Thermostats
CB120200-000 CB1202XX-200 RECB1202 Box RTBCB
CB120300-000 CB1203XX-200 RECB1203 Temperature Range
Sensing
CB120400-000 CB1204XX-200 RECB1204 Mounting Unit
RTMMB ON OFF
Brackets
80 °F (27 °C) 100 °F (38 °C) FSU8
CB125100-000 CB1251XX-200 RECB1251 100 °F (38 °C) 120 °F (49 °C) FSU10
CB125800-000 CB1258XX-200 RECB1258 120 °F (49 °C) 140 °F (60 °C) FSU12
CB125200-000 CB1252XX-200 RECB1252
Adjustable 90 ° – 130 °F
CB125700-000 CB1257XX-200 RECB1257 FSU90-130
(32 ° – 54 °C)
CB125300-000 CB1253XX-200 RECB1253
CB125400-000 CB1254XX-200 RECB1254 Example:
Model Number: CB115110-200

T-Stat Replacement: FSU10
CB Model
with thermostat assembly Element O-Ring ADAPTER FITTINGS
For the use of 0.75” or 1”
ID heater hose, hose barb
adapters are available.
Replacement See below.
Tank
1” NPT to 1” hose
Replacement barb adapter.
g HB-1 Installs in 1” NPT
Temperature tin Box
un ets High Limit female inlet or
Sensing Mo rack
Unit B Control outlet of the heater.
Replacement 1” NPT to 0.75”

Element hose barb adapter.
HB-3/4 Installs in 1” NPT
female inlet or
outlet of the heater.
Check Valve

Thermosiphon Engine Model Number
Model Number
Displacement without Thermostat
Engine Heaters see chart 1
CL130100-100 CL1301XX-200 120 3000 1 25.0

CL Model 800 – 1000 CID CL130800-100 CL1308XX-200 208 3000 1 14.4
CL130200-100 CL1302XX-200 240 3000 1 12.5
Weathertight CL130700-100 CL1307XX-200 277 3000 1 10.8
13.1 – 16.4 L
Single Phase CL130300-100
CL130400-100
CL1303XX-200
CL1304XX-200
380
480
3000
3000
1
1
7.9
6.3
CL140800-100 CL1408XX-200 208 4000 1 19.2
1500–5000 Watts 1000 – 1350 CID CL140200-100 CL1402XX-200 240 4000 1 16.7
CL140700-100 CL1407XX-200 277 4000 1 14.4
16.4 – 22.1 L CL140300-100 CL1403XX-200 380 4000 1 10.5
CL140400-100 CL1404XX-200 480 4000 1 8.3
CL150800-100 CL1508XX-200 208 5000 1 24.0
1350 – 1650 CID CL150200-100 CL1502XX-200 240 5000 1 20.8
CL150700-100 CL1507XX-200 277 5000 1 18.1
22.1 – 27.0 L CL150300-100 CL1503XX-200 380 5000 1 13.2
CL150400-100 CL1504XX-200 480 5000 1 10.4
CHART 1 CL Model
Heaters with Thermostats
19.5” 5.25”
To specify temperature range of 495mm 133mm
thermostat, insert numerical code OUTLET, 1” NPT
ADJUSTABLE FEMALE
from chart in place of the XX in model
number.
5.0”
CL M
Model without thermostat Example: 127mm
Desired Temp. Range: 100 ° – 120 °F
Model Number: CL1302XX-200 INLET, 1” NPT
FEMALE
Order as: CL130210-200

Code 23.5” 6.2”
ON OFF 597mm 157mm
OUTLET, 1” NPT
80 °F (27 °C) 100 °F (38 °C) 08 ADJUSTABLE FEMALE
100 °F (38 °C) 120 °F (49 °C) 10
120 °F (49 °C) 140 °F (60 °C) 12 5.8”
CL Model with thermostat 147mm
A3 INLET, 1” NPT
(32 ° – 54 °C)
FEMALE
OEM Replacement HOTSTART Caterpillar Pre-Wired

Volts Watts Phase Amps
Model Number Model Number at assembly
Weathertight
25.0 @ 120 V
Single Phase CL130DA2-000 7E-6247 120/240 120 3000 1
12.5 @ 240 V
16.7 @ 240 V
CL140EA2-000 — 240/480 240 4000 1
3000–6000 Watts 8.3 @ 480 V
7E-6248 25.0 @ 240 V
CL160EA2-000 240/480 240 6000 1
(2006504) 12.5 @ 480 V
25.0
CL160CA2-000 7E-6249 120 2-120 V circuits 6000 1
per circuit
NOTE: Vertical installation ONLY
For original equipment replacement: 4.7”

• Two 5” stainless steel clamps are OUTLET
1” NPT 119mm
included to mount heater to existing NIPPLE
bracket.
5.8”
For new installations: 147mm
• U-bolt mounting brackets available. 20.4”
Order kit number: FK9 518mm
Vertical Mount
OEM replacement
INLET, 1” NPT
NIPPLE

Model Number
Model Number
with Element Common Replacement Parts
without
Thermostat
Thermostat Replacement available for all listed heaters Replacement Parts
see chart 2
CL130100-100 CL1301XX-200 RECL1301-100 High Limit
CL130800-100 CL1308XX-200 RECL1308-100 Control
CL130200-100 CL1302XX-200 RECL1302-100
CL130700-100 CL1307XX-200 RECL1307-100 engine heaters
Check Valve RV-M
CL130300-100 CL1303XX-200 RECL1303-100 CL Model
CL130400-100 CL1304XX-200 RECL1304-100
CL140800-100 CL1408XX-200 RECL1408-100 Element O-ring TML-OR
CL140200-100 CL1402XX-200 RECL1402-100
CL140700-100 CL1407XX-200 RECL1407-100 CHART 2
CL140300-100 CL1403XX-200 RECL1403-100 Tank RTL
CL140400-100 CL1404XX-200 RECL1404-100
CL150800-100 CL1508XX-200 RECL1508-100 Box RTBCL-100
CL150200-100 CL1502XX-200 RECL1502-100 Temperature Range
Sensing
CL150700-100 CL1507XX-200 RECL1507-100 Mounting Unit
CL150300-100 CL1503XX-200 RECL1503-100 FK7 ON OFF
Brackets
CL150400-100 CL1504XX-200 RECL1504-100
80 °F (27 °C) 100 °F (38 °C) FSU8
100 °F (38 °C) 120 °F (49 °C) FSU10
120 °F (49 °C) 140 °F (60 °C) FSU12
CL Model
with thermostat assembly FSU90-130
Element O-Ring (32 ° – 54 °C)
Replacement
Tank Example:
Temperature Model Number: CL130210-200

Sensing T-Stat Replacement: FSU10
Unit ng
unti
Mo ackets
B r
Replacement
High Limit
Box
Control
Replacement
Element
Check Valve
HOTSTART Element Common Replacement Parts Replacement Parts

Model Number Replacement available for all OEM replacement heaters
CL130DA2-000 RECL130D Thermostat AMT70210-A2
For thermosiphon
CL140EA2-000 RECL140E Element O-ring TML-OR
engine heaters
CL160EA2-000 RECL160C Tank RTCSM OEM Replacement
CL160CA2-000 RECL140E Box RTBCL-100
CL OEM Replacement
Element O-Ring
Replacement
Tank
Replacement
Box
Thermostat
Replacement CL Model
Element with thermostat

Thermosiphon Engine
Model Number
without
Model Number
Displacement
Engine Heaters Thermostat see chart 1
SB Model SB115100-000 SB1151XX-200 120 1500 1 12.5

350 – 500 CID SB115800-000 SB1158XX-200 208 1500 1 7.2
with power cord
SB115200-000 SB1152XX-200 240 1500 1 6.3
Weathertight 5.7 – 8.2 L
SB115700-000 SB1157XX-200 277 1500 1 5.4
Single Phase
1500–2500 Watts 500 – 600 CID SB120100-000 SB1201XX-200 120 2000 1 16.7
SB120800-000 SB1208XX-200 208 2000 1 9.6
8.2 – 9.8 L SB120200-000 SB1202XX-200 240 2000 1 8.3
SB122100-000 SB1221XX-200 120 2250 1 18.8

600 – 800 CID SB125800-000 SB1258XX-200 208 2500 1 12.0
9.8 – 13.1 L SB125200-000 SB1252XX-200 240 2500 1 10.4
SB125700-000 SB1257XX-200 277 2500 1 9.0
Power cord length on all models – 72” (1829 mm)

All 208 V and 277 V models come with cord only - no plug.
CHART 1

To specify temperature range of thermostat, ON OFF Code
insert numerical code from chart in place of
80 °F (27 °C) 100 °F (38 °C) 08
SB Model with power cord the XX in model number.
100 °F (38 °C) 120 °F (49 °C) 10
no thermostat Example: 12
120 °F (49 °C) 140 °F (60 °C)
Model Number: SB1151XX-200 Adjustable 90 ° – 130 °F
A3
Order as: SB115110-200 (32 ° – 54 °C)
SB Model
17.2” 4.1”
SB Model with thermostat 437mm 104mm
OUTLET, 1” NPT
and power cord 5.75” FEMALE
146mm
4.3”
109mm
INLET, 1” NPT
FEMALE
21.2” 5.1”
538mm 129mm
OUTLET, 1” NPT
5.75” FEMALE
146mm
5.2”
132mm
INLET, 1” NPT
FEMALE

Model Number
Model Number
with Element Power Common Replacement Parts
without
Thermostat
Thermostat Replacement Cord available for all listed heaters Replacement Parts
see chart 2
High Limit
HLC-165
SB115100-000 SB1151XX-200 RESB1151 RHB-1-15 Control For thermosiphon
SB115800-000 SB1158XX-200 RESB1158 RHB-WOP
Check Valve RV-M
engine heaters
SB115200-000 SB1152XX-200 RESB1152 RHB-2-15
SB Model
Element O-ring TMM-OR
SB120100-000 SB1201XX-200 RESB1201 RHB-1-20 Tank RTB CHART 2

SB120200-000 SB1202XX-200 RESB1202 RHB-2-15 Heaters with Thermostats
Box RTBSB
Temperature Range
Sensing
Mounting
RTMMB Unit
SB122100-000 SB1221XX-200 RESB1221 RHB-1-20 Brackets ON OFF
SB125800-000 SB1258XX-200 RESB1258 RHB-WOP 80 °F (27 °C) 100 °F (38 °C) FSU8
SB125200-000 SB1252XX-200 RESB1252 RHB-2-15 100 °F (38 °C) 120 °F (49 °C) FSU10
SB125700-000 SB1257XX-200 RESB1257 RHB-WOP 120 °F (49 °C) 140 °F (60 °C) FSU12
Adjustable 90 ° - 130 °F
FSU90-130
(32 ° - 54 °C)
Example:
Model Number: SB115110-200

SB Model
with thermostat assembly
Element
O-Ring
Replacement
Tank
g
tin
Temperature
o un kets Replacement
Sensing M rac
Unit B Box
High Limit
Control
ADAPTER FITTINGS
Replacement For the use of 0.75” or 1”
Element ID heater hose, hose barb
adapters are available.
See below.
barb adapter.
HB-1 Installs in 1” NPT
Check Valve female inlet or
1” NPT to 0.75”
hose barb adapter.
female inlet or

Thermosiphon Engine
Model Number
without
Model Number
Displacement
SL Model SL130800-100 SL1308XX-200 208 3000 1 14.4

800 – 1000 CID
with power cord SL130200-100 SL1302XX-200 240 3000 1 12.5
Weathertight 13.1 – 16.4 L SL130700-100 SL1307XX-200 277 3000 1 10.8
Single Phase
3000–4000 Watts 1000 – 1350 CID SL140800-100 SL1408XX-200 208 4000 1 19.2
SL140200-100 SL1402XX-200 240 4000 1 16.7
16.4 – 22.1 L SL140700-100 SL1407XX-200 277 4000 1 14.4
Power cord length on all models – 72” (1829mm)

All 208 V and 277 V models come with cord only - no plug.
CHART 1

To specify temperature range of thermostat, ON OFF Code
insert numerical code from chart in place of
80 °F (27 °C) 100 °F (38 °C) 08
the XX in model number.
SL Model with power cord 100 °F (38 °C) 120 °F (49 °C) 10
Example: 120 °F (49 °C) 140 °F (60 °C) 12
no thermostat Desired Temp. Range: 100 ° – 120 °F
Model Number: SL1302XX-200 Adjustable 90 ° – 130 °F
A3
Order as: SL130210-200 (32 ° – 54 °C)
SL Model
19.5” 5.25”
SL Model with thermostat 495mm 133mm
and power cord ADJUSTABLE
OUTLET, 1” NPT
FEMALE
5.0”
127mm
INLET, 1” NPT
FEMALE
23.5” 6.2”
597mm 157mm
OUTLET, 1” NPT
ADJUSTABLE FEMALE
5.8”
147mm
INLET, 1” NPT
FEMALE

Model Number
Model Number
with Element Power Common Replacement Parts
without
Thermostat
Thermostat Replacement Cord available for all listed heaters Replacement Parts
see chart 2
High Limit
SL130800-100 SL1308XX-200 RESL1308-100 RHL-WOP Control
SL130200-100 SL1302XX-200 RESL1302-100 RHL-2-15 engine heaters
Check Valve RV-M
SL130700-100 SL1307XX-200 RESL1307-100 RHL-WOP SL Model
Element O-ring TML-OR
SL140800-100 SL1408XX-200 RESL1408-100 RHL-WOP Tank RTL CHART 2

SL140200-100 SL1402XX-200 RESL1402-100 RHL-2-20
SL140700-100 SL1407XX-200 RESL1407-100 RHL-WOP Box RTBCL-100
Temperature Range
Sensing
Mounting Unit
FK7 ON OFF
Brackets
80 °F (27 °C) 100 °F (38 °C) FSU8
100 °F (38 °C) 120 °F (49 °C) FSU10
120 °F (49 °C) 140 °F (60 °C) FSU12
Adjustable 90° – 130°F

FSU90-130
(32° – 54°C)
Example:
SL Model Model Number: SL130210-200

with thermostat assembly High Limit T-Stat Replacement: FSU10
Control
Element
O-Ring
Replacement ADAPTER FITTINGS

Tank
For the use of 0.75” or 1” ID
heater hose, hose barb adapters
are available.
See below.
Temperature g
Sensing tin
o un kets
Unit M rac Replacement 1” NPT to 1” hose
B Box barb adapter.
Replacement female inlet or
Element outlet of the heater.
1” NPT to 0.75”
hose barb adapter.
female inlet or
Check Valve

Thermosiphon Engine
Model Number
without
Model Number
Displacement
WL325800-000 WL3258XX-200 208 2500 3 6.9

WL Series WL325200-000 WL3252XX-200 240 2500 3 6.0
600 – 800 CID
Weathertight WL325A00-000 WL325AXX-200 400 2500 3 3.6
Three Phase 9.8 – 13.1 L WL325400-000 WL3254XX-200 480 2500 3 3.0
WL325500-000 WL3255XX-200 575 2500 3 2.5
2500–5000 Watts WL340800-000 WL3408XX-200 208 4000 3 11.1

1000 – 1350 CID WL340200-000 WL3402XX-200 240 4000 3 9.6
WL340A00-000 WL340AXX-200 400 4000 3 5.8
16.4 – 22.1 L WL340400-000 WL3404XX-200 480 4000 3 4.8
WL340500-000 WL3405XX-200 575 4000 3 4.0
WL350800-000 WL3508XX-200 208 5000 3 13.9

1350 – 1650 CID WL350200-000 WL3502XX-200 240 5000 3 12.0
WL350A00-000 WL350AXX-200 400 5000 3 7.2
22.1 – 27.0 L WL350400-000 WL3504XX-200 480 5000 3 6.0
WL350500-000 WL3505XX-200 575 5000 3 5.0
CHART 1
WL Model without thermostat Temperature Range All 3 phase heaters
Heaters with Thermostats Numerical
Code with thermostat must
To specify temperature range of ON OFF
use a control box.
thermostat, insert numerical code
See Control Systems
from chart in place of the XX in 80 °F (27 °C) 100 °F (38 °C) 08 page 34.
model number. 100 °F (38 °C) 120 °F (49 °C) 10
Example: 120 °F (49 °C) 140 °F (60 °C) 12
Model Number: WL3252XX-200 Adjustable 90 ° – 130 °F
Order as: WL325210-200 A3
(32 ° – 54 °C)
WL Model with thermostat

W
WL Model
19.5” 5.25”
495mm 133mm
OUTLET, 1” NPT
ADJUSTABLE FEMALE
5.0”
127mm
INLET, 1” NPT
FEMALE
23.5” 6.2”
597mm 157mm
OUTLET, 1” NPT
ADJUSTABLE FEMALE
5.8”
147mm
INLET, 1” NPT
FEMALE

Model Number Model Number
Element Common Replacement Parts
without with Thermostat
Replacement available for all listed heaters Replacement Parts
Thermostat see chart 2
High Limit
WL325800-000 WL3258XX-200 REWL3258
Control
WL325200-000 WL3252XX-200 REWL3252
WL325A00-000 WL325AXX-200 REWL325A
engine heaters
Check Valve RV-M
WL325400-000 WL3254XX-200 REWL3254 WL Series
WL325500-000 WL3255XX-200 REWL3255
Element O-ring TML-OR
WL340800-000 WL3408XX-200 REWL3408
WL340200-000 WL3402XX-200 REWL3402 Tank RTL
CHART 2
WL340A00-000 WL340AXX-200 REWL340A Heaters with Thermostats
WL340400-000 WL3404XX-200 REWL3404 Mounting
FK7 Temperature Range
WL340500-000 WL3405XX-200 REWL3405 Brackets Sensing
Unit
ON OFF
WL350800-000 WL3508XX-200 REWL3508
WL350200-000 WL3502XX-200 REWL3502 80 °F (27 °C) 100 °F (38 °C) FSU8
WL350A00-000 WL350AXX-200 REWL350A 100 °F (38 °C) 120 °F (49 °C) FSU10
WL350400-000 WL3504XX-200 REWL3504 120 °F (49 °C) 140 °F (60 °C) FSU12
WL350500-000 WL3505XX-200 REWL3505
FSU90-130
(32 ° – 54 °C)
Example:
Model Number: WL325210-200

WL Model High Limit

with thermostat assembly Control
Replacement ADAPTER FITTINGS

Tank For the use of 0.75” or 1” ID
are available.
See below.
Replacement
Thermostat Mounting
Brackets 1” NPT to 1” hose
Element barb adapter.
O-Ring HB-1 Installs in 1” NPT
female inlet or outlet
of the heater.
Replacement
Element
1” NPT to 0.75”
hose barb adapter.
of the heater.
Check Valve

Thermosiphon Engine Model Number Model Number
Volts Watts Phase Amp
Displacement without Thermostat with Thermostat
Engine Heaters
EE Model 500cid
or less EE115100-000 EE115110-000 120 1500 1 12.5
Hazardous Location EE115800-000 EE115810-000 208 1500 1 7.2
Single Phase 8.2L EE115200-000 EE115210-000 240 1500 1 6.3
or less
1500-5000 Watts
500 - 600cid EE120100-000 EE120110-000 120 2000 1 16.7
EE120800-000 EE120810-000 208 2000 1 9.6
8.2 - 9.8L EE120200-000 EE120210-000 240 2000 1 8.3
600 - 800cid EE125800-000 EE125810-000 208 2500 1 12.0

EE125200-000 EE125210-000 240 2500 1 10.4
9.8 - 13.1L EE125400-000 EE125410-000 480 2500 1 5.2
800 - 1000cid EE130800-000 EE130810-000 208 3000 1 14.4

EE130200-000 EE130210-000 240 3000 1 12.5
13.1 - 16.4L EE130400-000 EE130410-000 480 3000 1 6.3
EE Model without thermostat
1000 - 1350cid EE140800-000 EE140810-000 208 4000 1 19.2

EE140200-000 EE140210-000 240 4000 1 16.7
16.4 - 22.1L EE140400-000 EE140410-000 480 4000 1 8.3
1350 - 1650cid
EE150400-000 EE150410-000 480 5000 1 10.4
22.1 - 27.0L
EE Model with thermostat

All heaters over 480 V
Heaters with Thermostats with a thermostat must
Code use a control box. See
EE Models are only available with a ON OFF
Control Systems page 34.
fixed setting temperature sensor.
100 °F (38 °C) 120 °F (49 °C) 10
EE Model
20.3” 5.3”
516mm OUTLET, 1” NPT 135mm
FEMALE
ADJUSTABLE
5.3”
135mm
INLET, 1” NPT
FEMALE
25.2” 6.9”
FEMALE
ADJUSTABLE
5.3”
135mm

Model Number
Model Number Element Common Replacement Parts
without
with Thermostat Replacement available for all listed heaters Replacement Parts
Thermostat
EE115100-000 EE115110-000 REEE1151 Check Valve RV-M For thermosiphon

EE115800-000 EE115810-000 REEE1158
EE115200-000 EE115210-000 REEE1152
engine heaters
Flange RF-L
EE115400-000 EE115410-000 E01541E-50NA-00 EE Model
Flange O-ring TML-OR
EE120100-000 EE120110-000 REEE1201
EE120800-000 EE120810-000 REEE1208 Tank RTL
EE120200-000 EE120210-000 REEE1202 Heaters with Thermostats
EE120400-000 EE120410-000 E02041E-50NA-00
MC-HL cable PRP104301-029
Temperature Range Sensing
Mounting Unit
FK7 ON OFF
Brackets
EE125800-000 EE125810-000 REEE1258
EE125200-000 EE125210-000 REEE1252
100 °F (38 °C) 120 °F (49 °C) RSU10
EE125400-000 EE125410-000 E02541E-C0NA-00
Example:
Model Number: EE130210-000

EE130800-000 EE130810-000 REEE1308 T-Stat Replacement: RSU10
EE130200-000 EE130210-000 REEE1302
EE130400-000 EE130410-000 E03041E-50NA-00
EE140800-000 EE140810-000 REEE1408

EE140200-000 EE140210-000 REEE1402
EE140400-000 EE140410-000 E04041E-50NA-00
EE150400-000 EE150410-000 E05041E-C0NA-00
EE Model
with thermostat assembly Flange &
O-Ring
ADAPTER FITTINGS
are available.
ing
u nt ts Replacement See below.
Replacement o e
M rack Element
Tank B
barb adapter.
Check Valve female inlet or outlet
of the heater.
1” NPT to 0.75”
hose barb adapter.
MC-HL Cable female inlet or outlet
of the heater.
Replacement
Thermostat

Thermosiphon Engine Model Number Model Number
Volts Watts Phase Amp
Displacement without Thermostat with Thermostat
Engine Heaters
500cid
EE Model or less EE315800-000 EE315810-000 208 1500 3 4.2
Hazardous Location EE315200-000 EE315210-000 240 1500 3 3.6
8.2L EE315400-000 EE315410-000 480 1500 3 1.8
Three Phase or less
1500-5000 Watts EE320800-000 EE320810-000 208 2000 3 5.6

500 - 600cid
EE320200-000 EE320210-000 240 2000 3 4.8
8.2 - 9.8L EE320400-000 EE320410-000 480 2000 3 2.4
600 - 800cid EE325800-000 EE325810-000 208 2500 3 6.9

EE325200-000 EE325210-000 240 2500 3 6.0
9.8 - 13.1L EE325400-000 EE325410-000 480 2500 3 3.0
800 - 1000cid EE330800-000 EE330810-000 208 3000 3 8.3

EE330200-000 EE330210-000 240 3000 3 7.2
EE Model without thermostat 13.1 - 16.4L EE330400-000 EE330410-000 480 3000 3 3.6
1000 - 1350cid EE340800-000 EE340810-000 208 4000 3 11.1

EE340200-000 EE340210-000 240 4000 3 9.6
16.4 - 22.1L EE340400-000 EE340410-000 480 4000 3 4.8
1350 - 1650cid EE350800-000 EE350810-000 208 5000 3 13.9

EE350200-000 EE350210-000 240 5000 3 12.0
22.1 - 27.0L EE350400-000 EE350410-000 480 5000 3 6.0
EE Model with thermostat
E
All 3 phase heaters with

Heaters with Thermostats thermostat must use a
Code control box. See Control
EE Models are only available with a ON OFF
Systems page 34.
fixed setting temperature sensor.
100 °F (38 °C) 120 °F (49 °C) 10
EE Model
20.3” 5.3”
FEMALE
ADJUSTABLE
5.3”
135mm
INLET, 1” NPT
FEMALE
25.2” 6.9”
FEMALE
ADJUSTABLE
5.3”
135mm

Model Number
Model Number Element Common Replacement Parts
without
with Thermostat Replacement available for all listed heaters Replacement Parts
Thermostat
EE315800-000 EE315810-000 E01583E-15NA-00 Check Valve RV-M For thermosiphon

EE315200-000 EE315210-000 E01523E-15NA-00 engine heaters
EE315400-000 EE315410-000 E01543E-15NA-00 Flange RF-L EE Model
Flange O-ring TML-OR
EE320800-000 EE320810-000 E02083E-25NA-00
EE320200-000 EE320210-000 E02023E-25NA-00
EE320400-000 EE320410-000 E02043E-25NA-00 Tank RTL
MC-HL cable PRP104301-029
Temperature Range Sensing
EE325800-000 EE325810-000 E02583E-30NA-00 Mounting Unit
FK7 ON OFF
EE325200-000 EE325210-000 E02523E-30NA-00 Brackets
EE325400-000 EE325410-000 E02543E-30NA-00
100 °F (38 °C) 120 °F (49 °C) RSU10
Example:
EE330800-000 EE330810-000 E03083E-30NA-00
EE330200-000 EE330210-000 E03023E-30NA-00 Model Number: EE330210-000
EE330400-000 EE330410-000 E03043E-30NA-00 T-Stat Replacement: RSU10
EE340800-000 EE340810-000 E04083E-50NA-00

EE340200-000 EE340210-000 E04023E-50NA-00
EE340400-000 EE340410-000 E04043E-50NA-00
EE350800-000 EE350810-000 E05083E-50NA-00

EE350200-000 EE350210-000 E05023E-50NA-00
EE350400-000 EE350410-000 E05043E-50NA-00
ADAPTER FITTINGS
EE Model
with thermostat assembly Flange &
O-Ring
are available.
See below.
barb adapter.
ing
u nt ts Replacement female inlet or outlet
Replacement o e
M rack Element of the heater.
Tank B
1” NPT to 0.75”
hose barb adapter.
Check Valve HB-3/4 Installs in 1” NPT
of the heater.
MC-HL Cable
Replacement
Thermostat

Installation Instructions for Thermosiphon Engine Heaters
The HOTSTART engine heater uses thermosiphon action – the natural expansion and rising action of a heated fluid – to circulate heated coolant
throughout an engine’s water jacket. Installation of the heating system is critical. Please refer to specific instructions that accompany your
HOTSTART engine heater or visit hotstart.com and select Installation Instructions, Manuals and Guides from the Resources tab.
For “V” engines larger than eight cylinders or Prior to heater installation, inspect the coolant supply. When mixing coolant, only use
over 1000 CID (15L), HOTSTART recommends deionized or distilled water and low-silicate antifreeze. Refer to your engine’s manufacturer
using a HOTflow ® heater. Please refer to recommendations. Do not exceed 60% antifreeze to 40% water ratio. Never add unmixed
pages 4-5 for heater selection. water and antifreeze to an engine. Do not add anti-leak or other coolant additives.
PREPARING PLUMBING
• Drain and flush cooling system to remove any debris present in the • Install isolation valves to port fittings.
engine’s cooling system.
• Route and install return hose. The return hose should continuously
• Select return port. The return port will allow heated coolant to rise from the heater to the return port.
return to the engine.
• Route and install supply hose. The supply hose should continuously
• Select supply port. The supply port will allow coolant to flow from descend from the supply port to the heater.
the engine to the heater.
• Refill cooling system with coolant. To prevent air pockets, refill
• Select fittings. Use the following table to determine the proper port coolant with return hose removed.
fitting size for your heater:
• Start engine. Allow engine to run until engine thermostat opens,
CB/CL/SB/SL 500–3000 watts 1/2 inch NPT purging air from cooling system. Engine must be run to eliminate air
CB/CL/SB/SL 3750–5000 watts 3/4 inch NPT from heating system before energizing heater.
WL/EE 1500–5000 watts 3/4 inch NPT WIRING
• Select hoses. Use the following table to determine the minimum • Connect heater to an appropriately rated power source. Ensure
hose inner diameter for your heater: power source is grounded and in accordance with local and national
CB/CL/SB/SL 500–3000 watts 3/4 inch electrical codes. If necessary, install control box:
CB/CL/SB/SL 3750–5000 watts 1 inch  If your heater is single-phase and rated up to 480 volts, your
WL/EE 1500–5000 watts 1 inch heater may be powered directly without the use of a control relay
or contactor.
HOTSTART recommends installing valves to isolate the heating
system in case of service. To minimize flow restriction, select full-flow  If your heater is three-phase or is single-phase and rated for over
ball isolation valves. 480 volts, the heater thermostats must be used in a control circuit
with a contactor for switching the main power to the heating
MOUNTING elements.
• Select a heater mounting position directly below the return port
and at least 6 inches (15 cm) below the lowest point of the engine’s
water jacket. Mount heater using the supplied mounting brackets
and fasteners.
RETURN PORT
• Select a return port away from the engine thermostat.
• Select a return port high on the engine.
• Select a return port toward the rear of the engine.
• Select a return port away from the remote thermostat.
NOTE: If an optional remote thermostat is installed
• Select a return port away from the supply port.
SUPPLY PORT
• Select a supply port low on the engine.
• Select a supply port toward the front of
the engine.
• Select a supply port away from the
return port.
HEATER MOUNTING
• Mount the heater in the proper orientation. Ensure
heater outlet faces upward.
• Mount the heater to a vibration-isolated surface.
• Mount the heater directly below the return port.
• Mount the heater at least 6 inches (15 cm) below the
lowest point of the water jacket.

SECTION 2
LUBE OIL AND INDUSTRIAL IMMERSION HEATERS

Use a thermostat with all lube oil heaters to protect the oil from overheating. Lube oil
heaters must always be installed in the sump with the entire heater submerged below the oil
Oil Heaters level at all times. See page 25 for remote thermostat part numbers.
*NOTE: If heating gear oil (medium weight viscosity), HOTSTART recommends using low
Oil Heaters up to 277 V AC meet watt density heaters.
recognized CSA standards for
safety or performance. Oil Weathertight Hazardous Watts/Sq
Weathertight Location Volts Watts Amps
Capacity Heater Only With Thermostat Inch
Heater Only
3/8” N.P.T. THREAD WITH A 2 1/8” (54mm) PROBE LENGTH

To specify temperature range
2 qt. (2L) OW005100-000 — — 120 50 .4 20.0
of thermostat, insert code from
or Less OW005200-000 — — 240 50 .2 20.0
chart in place of the XX in model
number. 1/2” N.P.T. THREAD WITH A 4” (101mm) PROBE LENGTH
Example: 2 - 6 qt. OW212100-000 OW2121XX-000 OE212100-000 120 125 1.0 24.6
Desired Temp. Range 80 °–100 °F 2 - 5.7L OW212200-000 OW2122XX-000 OE212200-000 240 125 .5 24.6
Model Number: OW2121XX-000 3/4” N.P.T. THREAD WITH A 5” (127mm) PROBE LENGTH
Order as: OW212108-000
1 - 5 gal. OW415100-000 OW4151XX-000 OE415100-000 120 150 1.3 14.6*
3.8 - 19L OW415200-000 OW4152XX-000 OE415200-000 240 150 .6 14.6*
Temperature Range
Code OW430100-000 OW4301XX-000 OE430100-000 120 300 2.6 29.3
ON OFF 5 - 15 gal.
OW430800-000 OW4308XX-000 OE430800-000 208 225 1.1 22.0
19 - 57L
OW430200-000 OW4302XX-000 OE430200-000 240 300 1.2 29.3
60 °F (16 °C) 80 °F (27 °C) 06
1” N.P.T. THREAD WITH A 5 1/4” (133mm) PROBE LENGTH
80 °F (27 °C) 100 °F (38 °C) 08
100 °F (38 °C) 120 °F (49 °C) 10 1 - 5 gal. OW615100-000 OW6151XX-000 OE615100-000 120 150 1.3 10.7*
3.8 - 19L OW615200-000 OW6152XX-000 OE615200-000 240 150 .6 10.7*
See p.25 for remote thermostat
OW630100-000 OW6301XX-000 OE630100-000 120 300 2.6 21.4
assembly part numbers.
OW630800-000 OW6308XX-000 OE630800-000 208 375 1.8 28.0
5 - 15 gal. OW630200-000 OW6302XX-000 OE630200-000 240 300 1.2 21.4
19 - 57L — — OE630700-000 277 265 1.0 19.0
— — OE630300-000 380 300 1.0 21.4
— — OE630400-000 480 300 .6 21.4
OW650100-000 OW6501XX-000 OE650100-000 120 500 4.1 35.7
OW650800-000 OW6508XX-000 OE650800-000 208 450 2.2 33.0
OW650200-000 OW6502XX-000 OE650200-000 240 500 2.0 35.7
15 - 30 gal.
OW650700-000 OW6507XX-000 OE650700-000 277 400 1.4 30.0
57 - 113L
— — OE650300-000 380 500 1.3 35.7
— — OE650400-000 480 500 1.0 35.7
— — OE650500-000 575 500 0.8 35.7
Oil heater with Y-cord and
remote thermostat
Weathertight models are furnished with a 4’ (1.2m) oil- and heat-resistant power cord
without plug. Hazardous Location models are furnished with 18” (457mm) of lead wire for
connection to the power leads in an approved splice box.
DC Oil Heaters Oil 1/2” NPT with 3/4” NPT with 1” NPT with Watts Per
Capacity Volts Watts Probe
4” (101mm) 4 7/8” (124mm) 5 3/8” (136mm) Amps Square
12 V and 24 V Length Probe Length Probe Length Inch
2 qt.
When used with a thermostat 12 75 OW207900-012 OW407900-012 — 6.3 1/2” — 14.7* WSI
2.0L
control, all DC oil heaters 24 75 — OW407900-024 — 3.1 3/4” — 7.3* WSI
or Less
must use a DC relay.
_ 2-6 qt.
24 125 OW212900-024 — — 5.2 24.6 WSI
12 or 24 Magnetic 2.0-2.7L
V DC Contactors
+ 1-5 gal. 12 150 — OW415900-012 OW615900-012 12.5 3/4” — 14.6* WSI
C1 C1 3.8-19L 24 150 — OW415900-024 OW615900-024 6.3 1” — 10.7* WSI
C1 5-15 gal. 12 300 — — OW630900-012 25.0 3/4”— 29.3 WSI

DIT COIL Oil Heater 19-57L 24 300 — OW430900-024 OW630900-024 12.5 1” — 21.4 WSI
12 Vdc/24 Vdc 15-30 gal.

24 500 — — OW650900-024 20.8 35.7 WSI
CONTROL BOXES 57-113L
25 Amps 12V JBMC330DC-12V 12 V DC and 24 V DC oil heaters can be powered directly from the battery, but will drain the
Maximum 24V JBMC330DC-24V battery very rapidly unless charged by an alternator or generator.

Weathertight Hazardous Location
Heater only Heater only
9.70”
6.70” 246mm
170mm
5.25”
133mm 5.25”
133mm
Probe Length Probe Length
1.00” Dia.
25mm 1.00” Dia.
25.5mm
1.00” NPT 1.00” NPT
9.40”
6.40” 239mm
163mm
5.00”
127mm 5.00”
Probe Length 127mm
Probe Length
0.75”
19mm 0.75”
19mm
3/4” NPT 3/4” NPT
8.30”
6.50” 211mm
165mm
4.00”
102mm 4.00”
Probe Length 102mm
0.50” Dia. Probe Length
13mm 0.50” Dia.
13mm
1/2” NPT
1/2” NPT
REMOTE THERMOSTATS for OIL HEATERS Switch Capacity
Hazardous Temprature Range Sensing 120 V - 15amp

Weathertight Thread Size
Location ON OFF Unit 208 V - 10amp
240 V - 10amp
DIT68 DIT68EP 60 °F (16 °C) 80 °F (27 °C) LSU-6 1/2” NPT
277 V - 10amp
}
12 V DC Pilot
DIT1214 DIT1214EP 120 °F (49 °C) 140 °F (60 °C) LSU-12 1/2” NPT Duty
24 V DC Only
3.375” 5.50”
86mm 140mm
1.625” 1.625”
41mm 41mm
Probe Probe
Length Length
0.60” Dia.
15mm 3.25” 0.60” Dia.
83mm 15mm
3’ (1m) 16-3
HPN cord 1/2” NPT
1/2” NPT

Industrial Immersion
Models for larger capacities than shown are available. Call factory.
Heaters
2” Screw Plug HIGH LIMIT THERMOSTAT CONTROL SETTING
Oil Watts/
Volts Watts Amps
Capacity On 60 °F (16 °C) On 80 °F (27 °C) On 100 °F (38 °C) Sq. In.
Available with fixed or Off 80 °F (27 °C) Off 100 °F (38 °C) Off 120 °F (49 °C)
adjustable thermostat.
SINGLE PHASE — 2” N.P.T. WITH A 12” (305mm) PROBE LENGTH
30 - 45 E01011W-156A-00 E01011W-158A-00 E01011W-151A-00 120 1000 8.3 17.0

Gallons E01081W-156A-00 E01081W-158A-00 E01081W-151A-00 208 1000 4.8 17.0
E01021W-156A-00 E01021W-158A-00 E01021W-151A-00 240 1000 4.2 17.0
113-170L E01071W-156A-00 E01071W-158A-00 E01071W-151A-00 277 1000 3.6 17.0
45 - 60 E01511W-156A-00 E01511W-158A-00 E01511W-151A-00 120 1500 12.5 17.0

E01521W-156A-00 E01521W-158A-00 E01521W-151A-00 240 1500 6.3 17.0
C US
170-227L E01571W-156A-00 E01571W-158A-00 E01571W-151A-00 277 1500 5.4 17.0
THREE PHASE — 2” N.P.T. WITH A 12” (305mm) PROBE LENGTH

Weathertight Model
NEMA 4 30 - 45 E01083W-106A-00 E01083W-108A-00 E01083W-101A-00 208 1000 2.8 11.0
E01033W-106A-00 E01033W-108A-00 E01033W-101A-00 380 1000 1.5 11.0
113-170L E01043W-106A-00 E01043W-108A-00 E01043W-101A-00 480 1000 1.2 11.0
45 - 60 E01583W-156A-00 E01583W-158A-00 E01583W-151A-00 208 1500 4.2 17.0

E01533W-156A-00 E01533W-158A-00 E01533W-151A-00 380 1500 2.3 17.0
170-227L E01543W-156A-00 E01543W-158A-00 E01543W-151A-00 480 1500 1.8 17.0
C US
SINGLE PHASE — 2” N.P.T. WITH A 18” (457mm) PROBE LENGTH
(LVD only)
E02011W-156A-00 E02011W-158A-00 E02011W-151A-00 120 2000 16.7 14.0
60 - 90 E02081W-156A-00 E02081W-158A-00 E02081W-151A-00 208 2000 9.6 14.0
Hazardous Location Model E02071W-156A-00 E02071W-158A-00 E02071W-151A-00 277 2000 7.2 14.0
NEMA 4 & 7 227-341L E02031W-156A-00 E02031W-158A-00 E02031W-151A-00 380 2000 5.3 14.0
E02041W-156A-00 E02041W-158A-00 E02041W-151A-00 480 2000 4.2 14.0
THREE PHASE — 2” N.P.T. WITH A 18” (457mm) PROBE LENGTH
60 - 90 E02083W-156A-00 E02083W-158A-00 E02083W-151A-00 208 2000 5.6 14.0

E02033W-156A-00 E02033W-158A-00 E02033W-151A-00 380 2000 3.0 14.0
227-341L E02043W-156A-00 E02043W-158A-00 E02043W-151A-00 480 2000 2.4 14.0
Hazardous Location models with thermostat also available.

Substitute the letter “W” in part number with the letter “E” to specify Hazardous
Location models.
Industrial Immersion Heaters are also available for coolants and other process heating.
Call factory.
Call HOTSTART for complete model number featuring adjustable thermostat.

HOTSTART immersion heaters include a fixed-setting, built-in thermostat and are available Industrial Immersion
with an adjustable thermostat.
Heaters
Weathertight Model Hazardous Location Model
NEMA 4 NEMA 4 & 7 2” Screw Plug
12” or 18”
305mm or 457mm 12” or 18”
305mm or 457mm
4.3”
109mm 5.5”
140mm
3.6” 4.4”
91mm 112mm
Fixed Thermostat Assembly Adjustable Thermostat Assembly

NOTES:
On applications where
level of fluid is subject to
change, a liquid level switch
mounted a minimum of 3–4”
Adjustable
Thermostat
(76–102mm) above element
Control is recommended. Liquid
Thermostat level switch is not included
Sensor with heater.
Control
All 380 V and 480 V heaters
must be used in conjunction
with contactor and control
transformer.
All three phase models must
be used with a contactor.
See page 34.
Higher or lower temperature
ranges are available. Consult
TEMPERATURE RANGE CONTROL HOTSTART.
70 °– 210 °F
TEMPERATURE RANGE OFF AMT70-210
CONTROL (21 °– 99 °C)
ON OFF
60 °F (16 °C) 80 °F (27 °C) HLC-6 Nominal thermal differential is 8 °F (-13 °C)
80 °F (27 °C) 100 °F (38 °C) HLC-8
100 °F (38 °C) 120 °F (49 °C) HLC-10 ELECTRICAL RATING
ELECTRICAL RATING 30 Amps at 125 Vac
30 Amps at 240 Vac
15 Amps at 120 Vac
30 Amps at 277 Vac
10 Amps at 240 Vac
20 Amps at 480 Vac
10 Amps at 277 Vac

V-Clamp Immersion
Models for larger capacities than shown are available. Call factory.
Heaters
HIGH LIMIT THERMOSTAT CONTROL SETTING
Threadless Design Oil
Volts Watts Amps
Watts/
Capacity On 60 °F (16 °C) On 80 °F (27 °C) On 100 °F (38 °C) Sq. In.
Off 80 °F (27 °C) Off 100 °F (38 °C) Off 120 °F (49 °C)
Available with fixed or
adjustable thermostat.
SINGLE PHASE — WITH A 12” (305mm) PROBE LENGTH
30 - 45 E01011W-156V-00 E01011W-158V-00 E01011W-151V-00 120 1000 8.3 17.0

Gallons E01081W-156V-00 E01081W-158V-00 E01081W-151V-00 208 1000 4.8 17.0
E01021W-156V-00 E01021W-158V-00 E01021W-151V-00 240 1000 4.2 17.0
113-170L E01071W-156V-00 E01071W-158V-00 E01071W-151V-00 277 1000 3.6 17.0
45 - 60 E01511W-156V-00 E01511W-158V-00 E01511W-151V-00 120 1500 12.5 17.0

E01521W-156V-00 E01521W-158V-00 E01521W-151V-00 240 1500 6.3 17.0
C US 170-227L E01571W-156V-00 E01571W-158V-00 E01571W-151V-00 277 1500 5.4 17.0
THREE PHASE — WITH A 12” (305mm) PROBE LENGTH

Weathertight Model
NEMA 4
30 - 45 E01083W-106V-00 E01083W-108V-00 E01083W-101V-00 208 1000 2.8 11.0
E01033W-106V-00 E01033W-108V-00 E01033W-101V-00 380 1000 1.5 11.0
113-170L E01043W-106V-00 E01043W-108V-00 E01043W-101V-00 480 1000 1.2 11.0
45 - 60 E01583W-156V-00 E01583W-158V-00 E01583W-151V-00 208 1500 4.2 17.0

E01533W-156V-00 E01533W-158V-00 E01533W-151V-00 380 1500 2.3 17.0
170-227L E01543W-156V-00 E01543W-158V-00 E01543W-151V-00 480 1500 1.8 17.0
C US SINGLE PHASE — WITH A 18” (457mm) PROBE LENGTH
(LVD only) E02011W-156V-00 E02011W-158V-00 E02011W-151V-00 120 2000 16.7 14.0

60 - 90 E02081W-156V-00 E02081W-158V-00 E02081W-151V-00 208 2000 9.6 14.0
Hazardous Location Model E02071W-156V-00 E02071W-158V-00 E02071W-151V-00 277 2000 7.2 14.0
227-341L E02031W-156V-00 E02031W-158V-00 E02031W-151V-00 380 2000 5.3 14.0
NEMA 4 & 7
E02041W-156V-00 E02041W-158V-00 E02041W-151V-00 480 2000 4.2 14.0
THREE PHASE — WITH A 18” (457mm) PROBE LENGTH
60 - 90 E02083W-156V-00 E02083W-158V-00 E02083W-151V-00 208 2000 5.6 14.0

E02033W-156V-00 E02033W-158V-00 E02033W-151V-00 380 2000 3.0 14.0
227-341L E02043W-156V-00 E02043W-158V-00 E02043W-151V-00 480 2000 2.4 14.0
Hazardous Location models with thermostat also available.

Substitute the letter “W” in part number with the letter “E” to specify Hazardous
Location models.
Industrial Immersion Heaters are also available for coolants and other process heating.
Call factory.
Call HOTSTART for complete model number featuring adjustable thermostat.

HOTSTART immersion heaters include a fixed-setting, built-in thermostat and are available V-Clamp Immersion
with an adjustable thermostat.
Heaters
Weathertight Model Hazardous Location Model Threadless Design
NEMA 4 NEMA 4 & 7
12” or 18”
305mm or 457mm
12” or 18” Element assembly includes

305mm or 457mm O-ring only.
3.8” Installation kit sold separately.
97mm
5.3”
76mm V-CLAMP INSTALL KIT
Part
Weldable Parts Included
Number
Adapter
Weldable Steel weldable adapter
V-Clamp Adapter VC-SK V-Clamp
O-Ring
V-Clamp O-Ring
O-Ring
3.6” 4.4”
91mm 112mm
NOTES:
Fixed Thermostat Assembly Adjustable Thermostat Assembly On applications where
level of fluid is subject to
change, a liquid level switch
mounted a minimum of 3–4”
(76–102mm) above element
Adjustable is recommended. Liquid
Thermostat level switch is not included
Control
with heater.
Thermostat
Sensor All 380 V and 480 V heaters
Control
must be used in conjunction
with contactor and control
transformer.
All three phase heaters must
be used with a contactor.
See page 34.
Higher or lower temperature
ranges are available. Consult
HOTSTART.
TEMPERATURE RANGE CONTROL
70 °– 210 °F
TEMPERATURE RANGE OFF AMT70-210
CONTROL (21 °– 99 °C)
ON OFF
60 °F (16 °C) 80 °F (27 °C) HLC-6 Nominal thermal differential is 8 °F (-13 °C)
80 °F (27 °C) 100 °F (38 °C) HLC-8
100 °F (38 °C) 120 °F (49 °C) HLC-10 ELECTRICAL RATING
ELECTRICAL RATING 30 Amps at 125 Vac
30 Amps at 240 Vac
15 Amps at 120 Vac
30 Amps at 277 Vac
10 Amps at 240 Vac
20 Amps at 480 Vac
10 Amps at 277 Vac

SECTION 3
TEMPERATURE CONTROLS and CONTROL SYSTEMS

Temperature Controls
Remote Thermostats for Weathertight and Hazardous Location Oil Heaters (see p.24 for model numbers)
REMOTE THERMOSTATS for OIL HEATERS Switch Capacity
Hazardous Temprature Range Sensing 120 V - 15amp

Weathertight Thread Size
Location ON OFF Unit 208 V - 10amp
240 V - 10amp
DIT68 DIT68EP 60 °F (16 °C) 80 °F (27 °C) LSU-6 1/2” NPT 277 V - 10amp
}
LSU-12 1/2” NPT 12 V DC Pilot
DIT1214 DIT1214EP 120 °F (49 °C) 140 °F (60 °C) Duty
24 V DC Only
3.375” 5.50”
86mm 140mm
1.625” 1.625”
41mm 41mm
Probe Probe
Length Length
0.60” Dia.
15mm 3.25” 0.60” Dia.
83mm 15mm
3’ (1m) 16-3
HPN cord 1/2” NPT
1/2” NPT
Remote Adjustable Thermostat for TPS Thermosiphon Engine Heater (see p.7 for model numbers)
5/8” HB x 5/8” HB 2.6” 14-3 HPN

66mm 4’ (1.2m)
Part Adjustable Range

Sensing Unit
Number Temperature Setting
Adjustable 90 °–130 °F 3.7” 4.2”

TFTA-5/8HB FSU90-130 94mm 107mm
(32 °–54 °C)
Part number does not include “Y” cord
0.625” HOSEBARB
OUTLET HOSEBARB 0.625 I.D.
Power Y-cord
Adjustable
Thermostat 6.7”
Assembly 7.9” 170mm
201mm
In-Line INLET
Adjustable HOSEBARB
Thermostat 0.625 I.D.
Customer Support: 509.536.8660 hotstart.com 31

When using a thermostat above rated capacity or on 3 phase applications, select the
Temperature Controls proper control box with transformer and contactor as shown on page 34.
3.6”
92mm 1”NPT female x 1”NPT male
4X 1/2”
CONDUIT CONDUIT TYPE ENCLOSURE
KNOCKOUT
Temperature Maximum Capacity
Part Setting Ratings
Number 120/
1”NPT On Off 277V 480V
1”NPT 240V
(FEMALE)
(MALE)
TFTC8-200 80°F (27°C) 100°F (38°C) 25amp 22amp 12.5amp
4.3”
1.8” 110mm TFTC10-200 100°F (38°C) 120°F (49°C) 25amp 22amp 12.5amp
46mm
Adjustable 90 °–130 °F
4.8” TFTCA-200 25amp 22amp 12.5amp
(32 °–54 °C)
122mm
3.6”
92mm 1”NPT male x 1”NPT male
4X 1/2”
CONDUIT
KNOCKOUT CONDUIT TYPE ENCLOSURE
1”NPT Number 120/
(MALE) 1”NPT On Off 277V 480V
(MALE) 240V
4.3” TFTC8-220 80°F (27°C) 100°F (38°C) 25amp 22amp 12.5amp
1.8” 110mm
46mm
127mm (32 °–54 °C)
3.6”
92mm 1” hose barb x 1”NPT male
4X 1/2”
CONDUIT
KNOCKOUT CONDUIT TYPE ENCLOSURE
Number 120/
1”NPT On Off 277V 480V
1”HB (MALE) 240V
4.3” TFTC8-240 80°F (27°C) 100°F (38°C) 25amp 22amp 12.5amp
1.8” 110mm
46mm TFTC10-240 100°F (38°C) 120°F (49°C) 25amp 22amp 12.5amp
127mm (32 °–54 °C)
1/2" NPT HAZARDOUS LOCATION

Conduit
Opening CONDUIT TYPE ENCLOSURE
3.0”
76mm
5.0” Setting Ratings
127mm Part
Number 120/
On Off 277V 480V
240V
1.0” TFT10ER 100°F (38°C) 120°F (49°C) 25amp 22amp 12.5amp

1" NPT Inlet
1.25”
32mm 2.25”
57mm

When using a thermostat above rated capacity or on 3 phase applications, select the
proper control box with transformer and contactor as shown on page 34. Temperature Controls
3.6”
92mm 4X 1/2”
1”NPT female x 1”NPT male CONDUIT
KNOCKOUT
CORD CONNECTED
1”NPT
Number 120/ (FEMALE)
On Off 277V 1”NPT
240V
(MALE)
TFT8-200 80°F (27°C) 100°F (38°C) 15amp 15amp 5.4”
137mm
TFT10-200 100°F (38°C) 120°F (49°C) 15amp 15amp
TFT12-200 120°F (49°C) 140°F (60°C) 15amp 15amp
TFTA-200 15amp 15amp 1.8” 4.8”
(32 °–54 °C) 46mm 122mm
3.6”
92mm 4X 1/2”
1”NPT male x 1”NPT male CONDUIT
KNOCKOUT
CORD CONNECTED
Number 1”NPT
120/ (MALE)
On Off 277V
240V 1”NPT
(MALE)
TFT8-220 80°F (27°C) 100°F (38°C) 15amp 15amp 5.4”
137mm
TFT10-220 100°F (38°C) 120°F (49°C) 15amp 15amp
TFT12-220 120°F (49°C) 140°F (60°C) 15amp 15amp
TFTA-220 15amp 15amp 1.8” 5.0”
(32 °–54 °C) 46mm 127mm
3.6”
1” hose barb x 1”NPT male 92mm 4X 1/2”
CONDUIT
KNOCKOUT
CORD CONNECTED
Number 120/
On Off 277V 1”HB
240V 1”NPT
(MALE)
TFT8-240 80°F (27°C) 100°F (38°C) 15amp 15amp 5.4”
137mm
TFT10-240 100°F (38°C) 120°F (49°C) 15amp 15amp
TFT12-240 120°F (49°C) 140°F (60°C) 15amp 15amp
TFTA-240 15amp 15amp
(32 °–54 °C) 1.8” 5.0”
46mm 127mm
3.0”
REMOTE ADJUSTABLE 76mm
With 5’ (1.5m) Capillary Probe 1.9”
48mm
Maximum Capacity Ratings
Part Adjustable Range
120/208/ 3.4”
Number Temperature Setting 277V 480V 86mm
240V
65 - 250°F (18 - 121°C) 5.0”
(Open or Off Setting) 127mm
AT6525 25amp 22amp 5amp .078”
Differential 4°F (2.2°C) 5 250
2.0mm
6.4”
21
5 155 185
(Close or On Setting) Dia.

163mm
LO
12
60 95
ATW
Aluminum
Well for
AT6525 1/2” NPT
Customer Service:
509.536.8660 hotstart.com 33
Control systems allow for quick electrical installation of all HOTSTART engine heaters. They
are designed as a time and labor saving component. Control systems are especially useful
Control Systems on installations that require two coolant heaters or combinations of a coolant heater and oil
heater/hydraulic heater etc.
All control boxes on this page are NEMA 4, 12 & IP66.
CONTROL SYSTEMS
CONTROL SYSTEMS featuring AUTOMATIC SHUTDOWN DEVICES
With 24 V DC Relay
1 Heater, 1 Thermostat 2 Heaters, 2 Thermostats
Amps Volts
per application per application
30A Max 120 JBC11-100 JBC21-100

30A Max 208 JBC18-100 JBC28-100
30A Max 240 JBC12-100 JBC22-100
30A Max 400 JBC1A-100 JBC2A-100
30A Max 480 JBC14-100 JBC24-100
30A Max 575 JBC15-100 JBC25-100
Model JBC14-100 Model JBC24-100

See wiring schematic page 35 See wiring schematic page 35
All HOTSTART heaters with thermostat, operating on three phase current (at any voltage),
require the use of a control system with a 3-pole contactor. All HOTSTART heaters with
thermostat, operating over 480 V (single or three phase) require a control system to reduce
the primary voltage to 120 V for the control circuit. For increased thermostat life, use a
control system on all heaters above 277 V either single or three phase.
All control boxes can be used with either single or three phase heaters.
Control boxes are available in Hazardous Location models - contact factory for part number.
For heater protection and power savings, HOTSTART recommends de-energizing the heater
when engine is running. Control boxes are supplied with a 24 V relay to de-energize the
heater upon engine start-up.

Wiring Schematic for JBC14-100
USER SUPPLIED
CIRCUIT BREAKER
Control Systems
L3
MAIN L2
POWER
IN L1
MAGNETIC K1
CB1 CONTACTORS
EQUIPMENT GROUND
MUST BE GROUNDED CONTROL
H4 TRANSFORMER H1
480V PRIMARY
X1 X2
120V
50VA
CB2
HEATING
ELEMENT
A1 11
USER SUPPLIED
24VDC K2 N/C
SIGNAL 12
A2 Model JBC14-100
CONTACTOR
COIL
3 K1 2
4
USER SUPPLIED
THERMOSTAT
To control one 480 V heater at maximum 30 amps on manual start engine.
Wiring Schematic for JBC24-100

USER SUPPLIED
CIRCUIT BREAKER
L3
MAIN L2
POWER
IN L1
CB1 CB2 CB3

EQUIPMENT GROUND CONTROL
MUST BE GROUNDED TRANSFORMER
H4 480V PRIMARY H1
MAGNETIC K1 K2
CONTACTORS
X1 X2
120V
50VA
CB4
HEATING HEATING
ELEMENT ELEMENT
Model JBC24-100
A1
11
USER SUPPLIED
24VDC K3 N/C
SIGNAL 12
A2
CONTACTOR
COIL
3 K1 2
4
5
3 K2 2
CONTACTOR
USER SUPPLIED COIL
THERMOSTAT
To control two 480 V heaters at maximum 30 amps on automatic start engines.

POWER DISTRIBUTION BOX
Power Distribution
Use to simplify wiring on equipment when a variety of heaters and controls are required.
Box All models have ten, 25 Amp terminal blocks. Power Distribution Boxes are rated NEMA 4
and IP66/67
Part Number of
*Box comes assembled with 4 strain relief connectors. For
PDB-000 Number Openings additional connectors, order part# A6553-2.
PDB-000 8*
4.5” 3.0”
114mm 76mm
30 AMP
MAX
5 6 7 8 1 2 3 4
A6553-2 4.5”
114mm
8 7 6 5 4 3 2 1
OIL PRESSURE SWITCH

For automatic cut-off of heaters when engine starts.
Maximum Current Capacity:

120 V/208 V/240 V/277 V — 25 Amps
380 V/480 V/575 V — 15 Amps
Two pole single throw
To prevent overheating of the heating element

on standby equipment and automatic start
engines, HOTSTART recommends turning
the coolant heater off when the engine is
running. A pressure switch that senses engine
oil pressure is utilized to shut the heater off on
increase of oil pressure and to turn the heater
on when engine oil pressure drops.
NEMA 1
Part Number Enclosure Type
PS252 Dry Locations
PS252R Dry Locations (Reverse Action)
PS252WT Wet Locations
PS252EP Hazardous Locations

SECTION 4
BATTERY PADS/WRAPS
Battery Heating Model
Volts Watts Amps
Nominal Dimensions Battery
Style
Number Size
Pads A B
KB5015 120 50 .42 12.75” (324mm) 8.25” (210mm) 4D A

KB5015-S 120 50 .42 12.75” (324mm) 8.25” (210mm) 4D B
KB5015-D 120 50 .42 12.75” (324mm) 8.25” (210mm) 4D C
KB7515 120 75 .63 19.5” (495mm) 10.5” (267mm) 8D A

KB7515-S 120 75 .63 19.5” (495mm) 10.5” (267mm) 8D B
KB7515-D 120 75 .63 19.5” (495mm) 10.5” (267mm) 8D C
KB7523 240 75 .31 19.5” (495mm) 10.5” (267mm) 8D A

KB7523-S 240 75 .31 19.5” (495mm) 10.5” (267mm) 8D B
KB7523-D 240 75 .31 19.5” (495mm) 10.5” (267mm) 8D C
Battery heater not recommended
for nickel cadmium batteries.
When batteries are placed in
Typical Connection - 2 Batteries on Each Side of Vehicle
an insulated battery box, a
thermostat is recommended to Left Side Battery Box Right Side Battery Box
sense battery box temperature to
prevent overheating the battery.
KB7515-D
KB7515-D
KB7515-D
KB7515-S
Standard Pad for Single Battery
Style A
BEC-6
B Ground
BY-T68 BPC-61
6’ HPN
1.8m
Accessories For Multiple Battery Heating
Special Pads for Multiple Batteries
EXTENSION CORDS POWER SUPPLY CORDS
9.0” A
229mm Part Number Length Part Number Length Volts
Style B BEC-2 2’ (0.7m) BPC-31 3’ (1m) 120
B
BEC-4 4’ (1.2m) BPC-32 3’ (1m) 240
16-3 HPN
BEC-6 6’ (1.8m) BPC-61 6’ (1.8m) 120
BEC-8 8’ (2.4m) BPC-62 6’ (1.8m) 240
9.0” A
229mm
2’ (0.7m)
Style C 4’ (1.2m) 3’ (1m)
16-3 HPN B 6’ (1.8m) 6’ (1.8m)
8’ (2.4m)
16-3 HPN
THERMOSTAT & “Y” CORD ASSEMBLY 13.2” 13.5”

Temperature Control 335mm 343mm
Part
Number On Off
BY-T68 60°F (16°C) 80°F (27°C)
12.0”
CORD 305mm
16-3 HPN

BATTERY THERMAL WRAP — NO THERMOSTAT Battery Thermal
Model Number Volts Watts Length Wrap
KBW5015-000 120 50 28” (711mm)
KBW8015-000 120 80 36” (914mm)
KBW16015-000 120 160 72” (1829mm)
Prolong the life of your battery with HOTSTART thermal battery wraps with or without
thermostat.
• Durable, fire-retardant vinyl cover that resists oils and acids.
• All standard battery pads and battery wraps come with 6’ (1.8m) grounded cord
and plug.
• Fast, easy installation.
• Boosts battery cranking power as much as 75%.
BATTERY THERMAL WRAP — WITH THERMOSTAT

Thermostat range: 65°F - 80°F (18°C - 27°C)
Model Number Volts Watts Length
KBW5015T-000 120 50 28” (711mm)

KBW5024T-000 240 50 28” (711mm)
KBW8015T-000 120 80 44” (1118mm)

KBW8024T-000 240 80 44” (1118mm)
KBW10015T-000 120 100 56” (1422mm)

KBW10024T-000 240 100 56” (1422mm)
Thermostatically controlled battery thermal wraps provide optimum heating regardless of

ambient temperature.
• At 80°F (27°C), the battery will achieve maximum cold cranking amps.
• Battery is constantly maintained at 80°F (27°C).
• Provides greater heat rise than plates or pads.
• Thermostat will eliminate battery damage caused by overheating and acid spill.

Versatile and Easy to Install
Silicone Pad Heaters HOTSTART adhesive pad heaters can be used on 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.
• 120 V models are assembled with a standard 6’ (1.8m) HPN cord and plug. 240 V models
include 6’ (1.8m) HPN cord without plug.
Model Number Volts Watts Dimensions
Not for use on batteries AF10015 120 100 4” x 5”

AF10024 240 100 (102mm x 127mm)
AF15015 120 150 4” x 5”

AF15024 240 150 (102mm x 127mm)
AF25015 120 250 5” x 6”

AF25024 240 250 (127mm x 152mm)
AF40015 120 400 6” x 8”

AF40024 240 400 (152mm x 203mm)
Application
100 Watt 150 Watt 250 Watt 400 Watt
Guidline
2 - 5 quarts 5 - 8 quarts 2 - 5 gallons 5 - 8 gallons

Engine oil pan
1.9 - 4.7L 4.7 - 7.5L 7.5 - 19.0L 19.0 - 30.3L
5 - 7 gallons 7 - 10 gallons 10 - 20 gallons 20 - 30 gallons

Diesel Tank
19.0 - 26.5L 26.5 - 38.0L 38.0 - 75.7L 75.7 - 113.5L
1 - 5 gallons 5 - 10 gallons 10 - 20 gallons 20 - 30 gallons

Hydraulic Tank
4.0 - 19.0L 19.0 - 38.0L 38.0 - 75.7L 75.7 - 113.5L
up - 2 gallons 2 - 4 gallons 4 - 7 gallons 7 - 10 gallons

Water Tank
up - 7.5L 7.5 - 15.0L 15.0 - 26.5L 26.5 - 38.0L
CAUTION: Do not use pads with higher than recommended wattage for specific oil
capacities. For use on metal surfaces only.

SECTION 5
IN-BLOCK HEATERS and ACCESSORIES
41
In-block Heaters In-block heaters are complete with 2-wire w/ground 6’ (1.8m) HPN cord and plug.
For cord replacements or “Y” Thermocord energy saver, please reference page 52.
C US
Engine Model Part Number Part Number Watts Application Information Heat Shield Photo
120V 240V Required
Allis Chalmers
670T & I
AC-101 AC-102 1000 Replaces 1” thread-in plug on the oil cooler
685T & I at rear of the engine on right side.
6138LT, T & I CATV-151 CATV-152 1500 Not all of the engines have this opening.
25000 (844 CID)
Case/IH – Agricultural
CUB-751FP CUB-752FP 750
ALL 4 CYL 390 Inserts in any of the core plugs
ALL 6 CYL 590 on right side of engine.
Inserts in the core plug at right rear

ALL 6 CYL 830 CUC-151FP CUC-152FP 1500
of engine block.
Caterpillar
C-10 Replaces the threaded plug in the oil
TF121-000 TF122-000 1250 YES
C-12 cooler bonnet on the right side of engine.
C-9 Non ACERT C-9: Replaces 1” NPT plug in the right

rear of engine block.
C-15 Non ACERT CATV-151 CATV-152 1500 C-15, C-16: Replaces the threaded plug
C-16 Non ACERT in the back of the oil cooler.
C7 ACERT FP101-001 FP102-001 1000 Replaces the 44mm core plug on right side
YES
3126 FP151-001 FP152-001 1500 of engine just below the turbo charger.
Replaces the threaded 1-1/16” (1.0625”)

C7 ACERT rear port TL101-000 TL102-000 1000
plug in the rear of engine block.
Replace 1” NPT plug in the right rear

C9 ACERT CATV-151 CATV-152 1500
of engine block.
Replace any 1-5/16” (1.3125”) plug

C11 ACERT Check Exhaust
TF151-008 TF152-008 1500 in the rear of the oil cooler
C13 ACERT Routing
on right side of engine.
C15 ACERT Replace 1-3/16” (1.1875”) plug in rear of

TF151-009 TF152-009 1500
w/o breaksaver oil cooler on right side of engine.
C15 ACERT Replace any 1-5/16” (1.3125”) plug in the

TF151-008 TF152-008 1500
with breaksaver oil cooler on right side of engine.
C9 2007 ACERT
Replace any 1-3/16” (1.1875”) plug in rear
C13 2007 ACERT TF151-012 TF152-012 1500
of oil cooler on right side of engine.
C15 2007 ACERT
Replace the 1-1/2” (1.5”) plug

1674 CATB-151 CATB-152 1500
Replaces the water jacket access plate

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

1693T & 1693TA CATC-151-S CATC-152-S 1500
on left side of engine.
3013 1.5L Replaces 40mm core plug on the front

FP531-003 FP532-003 530
3014 2.0L left side of engine.

In-block heaters are complete with 2-wire w/ground 6’ (1.8m) HPN cord and plug.
In-block Heaters
C US
120V 240V Required
Caterpillar — Continued
Replaces 40mm core plug on the front left
3024 2.22L FP531-003 FP532-003 530 side of the engine.
Replaces 50mm core plug located at

3034 2.95L FP531-001 FP532-001 530
rear of head.
Replaces the plate in oil cooler case on

3044 3.3L PF531-001 PF532-001 530
left side of engine.
Replaces 35mm core plug located

3046 5.0L PF531-000 PF532-000 530
at rear of engine, left side.
3054 3.99L PER-751FP PER-752FP 750 Mounts in the 1-1/4” (1.25”) core plug
3054B 4.23L PER-101FP PER-102FP 1000 opening on left side of engine.
Mounts in 1-1/4” (1.25”) core plug at

3054C PER-751FP PER-752FP 750 right rear of engine with element
oriented in the 12 O’clock position.
Mounts in the 1-1/2” (1.5”) core plug

3056 6.0L PER-151FP PER-152FP 1500
Replaces the 44mm core plug on

3114 FP101-001 FP102-001 1000
right side of engine just below YES
3116 FP151-001 FP152-001 1500
the turbocharger.
DD8L-101 DD8L-102 1000 Replaces the 3/4” (0.75”) threaded plug

3176 10.3L
CAT-12015 CAT-12023 1250 on the right side of engine
through 1995
TF151-001 TF152-001 1500 just below the head.
3176 10.3L Replaces the 1” threaded plug in the oil

TF121-000 TF122-000 1250 YES
1996 and later cooler bonnet on right side of engine.
Replaces the 1” threaded plug in oil

3196 12.0L TF121-000 TF122-000 1250 YES
cooler bonnet on right side of engine.
3204 CATX-751 CATX-752 750 Replaces 44mm core plug on right rear
all 1100 series CATX-101 CATX-102 1000 side of engine.
Use on industrial engines when

3208 — 2 heaters 1500 clear access is available.
CATX-2-751-Y CATX-2-752-Y
with a single cord total Replaces any core plug - one on
each side of engine.
3208 JD3/4-101IN JD3/4-102IN 1000 Replaces any of the 3/4” (0.75”) or
Recommended JD1-101IN JD1-102IN 1000 1” plugs on the water transfer casting
aftermarket JD3/4-151IN JD3/4-152IN 1500 (right front of engine).
installation JD1-151IN JD1-152IN 1500 3/4” use JD3/4 — 1” use JD1
DD8L-101 DD8L-102 1000
3304 Replaces the 3/4” (0.75”) plug on
CAT-12015 CAT-12023 1250
3306 left side of engine.
TF151-001 TF152-001 1500
Replaces 1” threaded plug in the rear
AC-101 AC-102 1000
3406C/E 14.6L of the oil cooler bonnet on
CATV-151 CATV-152 1500
right side of engine.

C US
120V 240V Required
Caterpillar — Continued
3406 & 3408 Replaces 1” threaded plug in
AC-101 AC-102 1000
except 1998 the rear of the oil cooler bonnet
CATV-151 CATV-152 1500
ADEM 2 on right side of engine.
3406E Replaces the 1” threaded plug that points

1998 ADEM 2 TF151-002 TF152-002 1500 downward on the top of the rear of the oil YES
engines only cooler bonnet.
3406E Replaces 1” threaded plug in

AC-101 AC-102 1000
ADEM 3 and ADEM the rear of the oil cooler bonnet
CATV-151 CATV-152 1500
2000 engines on right side of engine.
Replaces 1” threaded plug in

AC-101 AC-102 1000
3456 15.8L the rear of the oil cooler bonnet
CATV-151 CATV-152 1500
Cummins
6 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 rear
Flat plate design when opening depending on clearance.
the 1/2” NPT opening CUN-151BH CUN-152BH 1500
is used
Group II
When an external oil cooler is Note: When a 4 bolt flat plate element design is encountered, remove the next two bolts on the casting, remove the
used.. whole casting, and replace the casting and element with either CNT-151B/CNT-152B OR CNT151B90/CNT152B90
When connection
6 bolt, flat plate design with an elbow
is 1 1/2” rubber hose
CNT-151B-90 CNT-152B-90 1500 that will rotate 360 degrees to connect
Engines produced Aug.
with any hose or casting.
1975 thru June 1982
Uses an “O” ring for

the 1 1/4” water tube 6 bolt, flat plate design with an elbow
connection CNT-151B CNT-152B 1500 that will rotate 360 degrees to connect
Engines produced prior with any hose or casting.
to August ‘75
Group III
For industrial engines

Six bolt flat plate on the right side
with hole pattern CUN-151BREV CUN-152BREV 1500
of engine block.
reversed
Group IV
1998 and later Six bolt flat plate on the right side
PF151-002 PF152-002 1500
N14 Industrial of engine block.

In-block Heaters
C US
120V 240V Required
Cummins — Continued
Cummins A Inserts in any of the core plugs on right
CUA-101F CUA-102F 1000
4 cyl & 6 cyl side of engine. Element points down.
ISC/QSC 8.3L DD8L-101 DD8L-102 1000 Replaces 3/4” (0.75”) NPT plug in
ISL/QSL 9.0L TF751-002 TF752-002 750 right front side of engine.
Inserts in the forward opening of

L10, M11
CUL-151 CUL-152 1500 the heater casting on the right rear
ISM 2007 of engine block.
QSB 3.9L, 5.9L Replaces 3/4” (0.75”) NPT plug in the

TF751-002 TF752-002 750
ISB 5.9 front of the oil cooler casting.
ISM/QSM 11.0L
PF151-003 PF152-003 1500 Right rear. Replaces plate.
Flat Plate Design
ISX, QSX
Mounts in the oval shaped plate on the
Signature 600 PF151-004 PF152-004 1500
right side of engine block.
Pre 2007
CUB-751FP CUB-752FP 750 Replaces 57.8mm core plug on Check Exhaust

4BT 3.9L
CUB-101FP CUB-102FP 1000 right side of engine. Routing

Replaces 57.8mm core plug on Check Exhaust
6BT 5.9L CUB-101FP CUB-102FP 1000
right side of engine. Routing
Replaces 57.8mm core plug on

6CT 8.3L CUC-151FP CUC-152FP 1500
right rear side of engine.
Detroit Diesel
SERIES 10
PER-751FP PER-752FP 750 Mounts in the 1-1/4” (1.25”) core plug
4 cylinder
PER-101FP PER-102FP 1000 opening on either side of engine.
Phaser engines
SERIES 10
6 cylinder PER-151FP PER-152FP 1500
Phaser engines
DD8L-101 DD8L-102 1000 Mounts in the 3/4” (0.75”) NPT opening

SERIES 30
TF751-002 TF752-002 750 in engine block.
PER-751FP PER-752FP 750

SERIES 40 Mounts in the core plug opening on
INTA-121 INTA-122 1250
all versions right side of engine.
FR151-001 FR152-001 1500

C US
120V 240V Required
Detroit Diesel – continued

SERIES 50 Mounts in the 1” NPT opening in either water
AC-101 AC-102 1000 Yes on 1991
SERIES 60 pick up pipe (up to 1991) or in the 1” NPT
CATV-151 CATV-152 1500 opening on the oil cooler housing after 1991. and later
Pre 2007
Mounts in the triangle plate on the side

SERIES 55 PF151-000 PF152-000 1500
of engine block.
3-53, 4-53, 3-71, Mounts in the oval shaped plate on

4-71 with water cooled DD-751-S DD-752-S 750
air compressor engine block. Check clearance.
3-53, 4-53, 3-71, Mounts in the oval shaped plate on

4-71 without water DD-751 DD-752 750
cooled air compressor engine block. Check clearance.
6-71
Mounts in the oval shaped plate on
with water cooled air DD-151-S DD-152-S 1500
engine block. Check clearance.
compressor
6-71
without water cooled DD-151 DD-152 1500
air compressor
DD8L-101 DD8L-102 1000 Threads into the 3/4” (0.75”) NPT opening
8.2 L V-8 Diesel
TF751-002 TF752-002 750 on engine block.
6V-53
with water cooled air DD6V-751-S DD6V-752-S 750
compressor
6V-53
without water cooled DD6V-751 DD6V-752 750
air compressor
6V71 & 8V71 AC-101 AC-102 1000 Threads into 1” NPT plug in the front face
Alternate location CATV-151 CATV-152 1500 of engine block.
6V-71 & 8V-71

6V-92 & 8V-92 Mounts in the square plate
DDV-151B DDV-152B 1500
except GMC General on engine block.
models
6V92 & 8V92 Threads into the 3/4” (0.75”) NPT opening
DD8L-101 DD8L-102 1000
alternate location - in the oil cooler housing. Note - not all
TF751-002 TF752-002 750
threads into oil cooler engines have this opening.
Deutz
BF4L913 BF6L913
F3L912 F3L913 OLT221515
F6L913 and Use adapter kit to mount the 22mm
n/a 150
A22M48M heater in the 48mm opening.
1011 SERIES (adapter)
oil cooled engines

In-block Heaters
C US
120V 240V Required
Deutz – continued
1012 — 4 & 6 cyl PF751-000 PF752-000 750 Mounts in the oval shaped plate opening
1013 — 4 cyl PF121-001 PF122-001 1250 on the oil cooler casting.
PF121-001 PF122-001 1250 Mounts in the oval shaped plate opening

1013 6 cyl
PF751-000 PF752-000 750 on the top of the oil cooler.
1015 Replaces 30mm plug in water elbow

TL151-004 TL152-004 1500
6 & 8 cyl on front of engine.
2012 — 4 & 6 cyl

Replace oval shaped plate on the top of
without electric PF751-002 PF752-002 750
the oil cooler.
fuel injection
Ford
7.3L V-8 diesels TF751-002 TF752-002 750 Mounts in the 3/4” (0.75”) NPT plug
from 1994 on DD8L-101 DD8L-102 1000 in the engine’s block.
Hino
3.8L, 5.8L, 6.0L, 6.4L,
DD8L-101 DD8L-102 1000 Threads into 3/4” (0.75”) NPT opening
6.7L, H06C-T, H07C-B, YES
TF751-002 TF752-002 750 in engine block.
W04C-T, W06E
Isuzu
4BD1 6HE1
Replaces 1” NPT plug on left rear
6BD1 6SA1 TF401-001 NONE 400
of engine.
6BG1
Iveco
NEF 4cyl Mount in front opening on right side

PF751-001 PF752-001 750
NEF 6 cyl of engine block.
John Deere
Check
With 3/4” plug in the JD3/4-101IN JD3/4-102IN 1000 3/4” (0.75”) NPT opening in the rear
Exhaust
back of the block JD3/4-151IN JD3/4-152IN 1500 face of engine block.
Routing
With 1” plug in the JD1-101IN JD1-102IN 1000 1” NPT opening in the rear face
back of the block JD1-151IN JD1-152IN 1500 of engine block.
With 1-5/8” opening 1-5/8” (1.625”) threaded opening on

JDS-101 JDS-102 1000
on the side of the the side of the block in the water
JDS-151 JDS-152 1500
water jacket distribution channel.

C US
120V 240V Required
John Deere – continued

6105 (10.5L) AC-101 AC-102 1000
1” NPT opening in the oil cooler casting.
6125 (12.5L) CATV-151 CATV-152 1500
Komatsu
Inserts in the forward opening of
L10 (10L)
CUL-151 CUL-152 1500 the heater casting on the right rear
M11(11L) of engine block.
Threads into the core plug opening in

SA6D125 MA-151 MA-152 1500
engine block.
Kubota
B, L, M Series
D905 V1205
D1005 V1305
D1105 V1505 Replaces 1” NPT plug on left front
D3000B V4000B TF401-001 NONE 400
of engine.
D3200B V4300B
DH905 VH1205
DH1005 VH1305
Mack
Mid liner E3
MAM-101 MAM-102 1000 Mounts in rear face of block.
MS200 & MS250
Mid liner E5
MAM-151 MAM-152 1500 Mounts in the oil cooler bonnet.
MS300
E6 engines
Replaces 1-3/4” (1.75”) core plug
“smooth bore” MASB-151 MASB-152 1500
on side of engine.
1981 and later
E6 engines
threaded core
plug opening
Pre-1981 Mounts in any threaded
MA-151 MA-152 1500
END 465, 711, core plug opening.
EN438, 504, 707,
673, 675, 676
(1957 through 1981)
E7 Engines Mounts in the plate in either the front or

PF151-001 PF152-001 1500 rear face of the block in the water jacket
Except E-Tech water
PF101-000 PF102-000 1000 passage. For 2002 engine – mounts in
pump mount rear face of block.
E9, ENDT865, 866 and

1000 series V8 engines 2000 Threads into the 3/4” (0.75”) NPT opening
DD8L-101 DD8L-102
total on each side of engine block.
Use two heaters

In-block Heaters
C US
120V 240V Required
MAN
D2840
Replace oval shaped plate in lower water
D2842 PF121-003 PF122-003 1250 pipe on right side of engine.
D2848
Replace 3 bolt plate on left side of engine.

D2866 May require adapter if 3 bolt opening
PF151-006 PF152-006 1500 is not available on engine.
D2876
Consult customer service.
Massey Ferguson
3 cylinder
PER-751FP PER-752FP 750 Mounts in any of the 1-1/4” (1.25”) core
4 cylinder YES
PER-101FP PER-102FP 1000 plug openings in the engine.
6 cylinder
Mercedes Benz
MBE904
MBE906 Replaces 60mm core plug on right
PF101-001 PF102-001 1000
MBE924 rear of engine.
MBE925
Navistar/International
AC-101 AC-102 1000 Threads into a 1” NPT opening in the
V800 (796 CID)
CATV-151 CATV-152 1500 oil cooler bonnet.
INLINE 6 CYLINDER
— all series — INTA-121 INTA-122 1250 Replaces third or fourth core plug on left
side of engine. Element should point
312, 360, 414, 436, INTA-101 INTA-102 1000 toward 1 O’clock position.
466 & 530
7.3L & T444 TF751-002 TF752-002 750 Mounts in the 3/4” (0.75”) NPT plug in
1994 and later DD8L-101 DD8L-102 1000 the engine’s block.
9.0L — V8 diesel INT9-101F INT9-102F 1000 Mounts in a core plug.
Oliver
ALL EXCEPT 1265, TF751-002 TF752-002 750 Threads into a 3/4” (0.75”) NPT
1365 & 1900 DD8L-101 DD8L-102 1000 opening in the block.
Onan — See Cummins “A” Series

Perkins
3.152
4.236
PER-101FP PER-102FP 1000 opening on right side of engine.
6.354
103.15
104.22 FP531-003 FP532-003 530 Replaces core plug on left front of engine.
404.22

C US
120V 240V Required
Perkins – continued
700 Series Replaces 50mm core plug located at
FP531-001 FP532-001 530
704.30 rear of head.
Mounts in oval shaped plate on the left

800 Series PF531-001 PF532-001 530 front of the block.
FR751-002 FR752-002 750

1004 (right side) FR101-000 FR102-000 1000 opening on right side of engine.
PER-151FP PER-152FP 1500

1004 (left side)
PER-101FP PER-102FP 1000 opening on left side of engine.

1006 (6 Cyl) A & B PER-151FP PER-152FP 1500
Replaces 1-1/4” (1.25”) core plug on

FR531-000- FR532-000-
1103C 530 right rear of engine. Element should point
WOC WOC
towards 1 O’clock position.
PER-751FP PER-752FP 750 Mounts in 1-1/4” (1.25”) core plug

1104 (4 Cyl) C & D
PER-101FP PER-102FP 1000 opening on right side of engine.
Volvo
Replaces oval shaped plate on
D9 PF151-007 PF152-007 1500
right side of engine.
D12C Replaces oval shaped plate on

PF151-005 PF152-005 1500 YES
Prior to Serial #250502 right side of engine.
D12C Replaces oval shaped plate on

PF121-002 PF122-002 1250 YES
After Serial #250502 right side of engine.
TD60, TD61, TD70,

Mounts into threaded opening on
TD71, TD100, TD101, VT6-101 VT6-102 1000
left side of engine.
VE10, TD120, TD121
Yanmar
3T72HLE
4TN82E 1” NPT
TF401-001 NONE 400
D4T No replacement cord available.
YYDXL4.41
NOTE: The only replacement part for in-block heaters is the power cord. Please see the power cord section on page 52 for the
proper replacement cord set.
For thermostat control of in-block heaters, see page 52. The energy saver Thermocord is available in various temperature ranges.
Supplemental heat for engines using in-block heaters can be achieved by the installation of lube-oil heaters in the oil pan.
Reference pages 24 and 25 of this catalog or consult factory.

Instructions for: In-block Heater Installation
In-block heaters
Please refer to specific instructions that accompany heater.
THREADED PLUG TYPE HEATERS

A. Drain the cooling system. Please follow these steps to ensure proper operation of your
HOTSTART in-block heater.
B. Remove the recommended
core plug. (See instructions 1. Align cord with pins on the heater and press the cord into the
with heater) heater. Place clamp around cord & heater. DO NOT PLUG IN
HEATER YET!
C. Apply teflon tape to pipe
threads or grease to O-ring. 2. Route the cord, keeping away from hot or moving surfaces.
D. Thread heater into engine. 3. Re-fill the cooling system. Run engine until engine thermostat
opens and continue running for another 20 minutes to
eliminate air.
4. Stop engine and let cool. Check for leaks. Check coolant level.
5. Plug heater into power supply and test for proper operation.
Block should feel warm near heater.
PLATE TYPE HEATERS

A. Drain the cooling system. Please follow these steps to ensure proper operation of your
HOTSTART in-block heater.
plate. (See instructions with 1. Align cord with pins on the heater and press the cord into the
heater) heater. Place clamp around cord & heater. DO NOT PLUG IN
HEATER YET!
C. Clean the gasket area.
2. Route the cord, keeping away from hot or moving surfaces.
D. Apply gasket sealant to
plate and engine surfaces. 3. Re-fill the cooling system. Run engine until engine thermostat
opens and continue running for another 20 minutes to
E. Insert heater into engine. eliminate air.
Tighten bolts.
4. Stop engine and let cool. Check for leaks. Check coolant level.
5. Plug heater into power supply and test for proper operation.
Block should feel warm near heater.
FREEZE (CORE) PLUG TYPE HEATERS

A. Drain the cooling system. Please follow these steps to ensure proper operation of
your HOTSTART in-block heater.
core plug. (See instructions 1. Align cord with pins on the heater and press the cord into
with heater) the heater. Place clamp around cord & heater. DO NOT
PLUG IN HEATER YET!
C. Clean, smooth and dry core
plug opening. 2. Route the cord, keeping away from hot or moving surfaces.
D. If retaining ring style, apply 3. Re-fill the cooling system. Run engine until engine
a light coat of grease to thermostat opens and continue running for another 20
the O- ring and core plug minutes to eliminate air.
opening. If press-in style,
apply a light coat of high- 4. Stop engine and let cool. Check for leaks. Check coolant
temperature, high-strength level.
retaining compound (Loctite 5. Plug heater into power supply and test for proper operation.
640 recommended). Block should feel warm near heater.
E. Insert heater into engine
and position properly. Push
the heater into the engine
by hand, then tap in using a
suitable tool until flange is
even with engine block.

Replacement Cords
For use with In-block Heaters
& Thermostats
Cord Plug STYLE 1
120 Volt 240 Volt
Length Style C US
6’
1 IM6-1IN IM6-2IN
1.8m
15amp, 120V
11’
1 IM11-1IN IM11-2IN
3.4m
16’ 15amp, 240V

1 IM16-1IN IM16-2IN
4.8m
Fits most competitor’s applications.
Heat Shield
Cord Plug STYLE 2
120 Volt 240 Volt
Length Style C US
6’
HS1 2 11PR72T 21PR72T
1.8m
15amp, 120V
11’
2 11PR132T 21PR132T
3.4m
Use when exhaust manifold or turbo

come close to heater termination. 16’
2 11PR192T 21PR192T
4.8m 15amp, 240V
IM6-1IN
11PR72T
Thermocord for In-block Heaters C US
NOTE: When ordering in-block Thread

Part No. Volts Temp Range 4’ 3 ft.
heater and thermocord, place Size
1.2m 1m
suffix –WOC (which stands TC031310-866 120 1/2” 100 °–120 °F (38 °– 49 °C)
for without cord) after the
TC031312-866 120 1/2” 120 °–140 °F (49 °– 60 °C)
heater model number to save 3 ft.
cost as the standard 6’ (1.8m) 1m
TC032310-866 240 1/2” 100 °–120 °F (38 °– 49 °C)
heater cord is replaced by the
Thermocord harness. TC032312-866 240 1/2” 120 °–140 °F (49 °– 60 °C)
TC031308-866 120 1/2” 80 °–100 °F (27 °– 38 °C)
TC032308-866 240 1/2” 80 °–100 °F (27 °– 38 °C) Heater shown for illustration purposes only

Flush Mount Kits for In-block Heaters Flush Mount Kits &
Model Model
Number Number Cord Length
Plug
Style Kits include:
Accessories
120 Volt 240 Volt 11PR- style C US
cord (shown
IM6-1IN-FM IM6-2IN-FM 6’ (1.8.m) 2 on page 52),
recessed male
IM11-1IN-FM IM11-2IN-FM 11’ (3.4m) 2 receptacle and
hinged flip
cover.
IM16-1IN-FM IM16-2IN-FM 16’ (4.8m) 2
3.1”
79mm
3.0”
76mm
Flush Mount Kits for Thermosiphon Engine Heaters

Model For Heater with
Volts Amps
Number Wattage of: Kits include: C US
Recessed male
FM15120 120 15 500 to 1800 receptacle with 6’
(1.8m) cord (no female
connectors), hinged
FM15240 240 15 500 to 3000 flip cover and female
connector.
FM20120 120 20 2000 to 2250
3.1”
79mm
3.0”
76mm
Other Accessories
Recessed Male Receptacle – with 6’ (1.8m) cord (no female connectors)
Model Number Volts Amps
RM5-15 120 15
RM6-15 240 15
RM5-2Ø 120 20
RM6-2Ø 240 20
Female Connector - for extension cords
Model Number Volts Amps
FM1G2ØA 120 15/20

FM2G2ØA 240 15/20
Hinged Cover
Model Number Description 3.25” 3.1”

82mm 79mm
*FC-KH Black/HOTSTART Logo
FC-KH-C Chrome/HOTSTART Logo
3.0”
76mm
*Standard with kit
Plug Housing
Model Number
A-2223-PH

1. Determine the best type of heater to be used for the application.
Specifying an • In-block or Thermosiphon Engine Heater?
Engine Heater • Weathertight model for all indoor or outdoor applications (hospital, communications
building, shopping mall, pump station, off-road equipment).
• Hazardous Location model (off-shore platform, oil rig, gas compression station).
2. Determine engine size.

• Cubic inch or liter displacement.
3. Determine wattage required by using this general formula:

• 3 watts x cubic inch displacement = watts required.
Example: Engine is 855 CID. Requirement is 2500 watt heater. (855 x 3 = 2565)
• This formula is a very good rule of thumb to use down to 0 °F (-18 °C) ambient
temperature. This formula will generally hold engine temperature at approximately
100 °F (38 °C) above ambient.
• Engines over 1250 CID (20 L) and V-type engines require forced circulation preheating
systems (CTM, CSM models — see pages 4-5).
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 (38 °C) to 120 °F (49 °C) 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 preheater from the
many products listed in this catalog. For other technical information and installation tips, see
pages 22 and 51. If you have other questions or need additional assistance, please contact
our customer service department.
Cubic Inches - Litres Conversion Chart Temperature

Cubic Inches Litres Cubic Inches Litres Cubic Inches Litres Fahrenheit Celsius
Conversion Factors
150 2.46 1600 26.22 3050 49.98 -40 °F -40 °C
Litres x 1.0567 = Quarts 200 3.28 1650 27.04 3100 50.80 -30 °F -34 °C
Quarts x 0.94635 = Litres 250 4.10 1700 27.86 3150 51.62 -20 °F -29 °C
Litres x 0.26417 = Gallons 300 4.92 1750 28.68 3200 52.44 -10 °F -23 °C
Gallons x 3.7854 = Litres
350 5.74 1800 29.50 3250 53.26 0 °F -18 °C
400 6.55 1850 30.32 3300 54.08 10 °F -12 °C
450 7.37 1900 31.13 3350 54.90 20 °F - 7 °C
500 8.19 1950 31.95 3400 55.71 30 °F - 1 °C
550 9.01 2000 32.77 3450 56.53 40 °F 4.5 °C
600 9.83 2050 33.59 3500 57.35 50 °F 10.0 °C
650 10.65 2100 34.41 3550 58.17 60 °F 15.5 °C
700 11.47 2150 35.23 3600 58.99 70 °F 21.0 °C
750 12.29 2200 36.05 3650 59.81 80 °F 27.0 °C
800 13.11 2250 36.87 3700 60.63 90 °F 32.0 °C
850 13.93 2300 37.69 3750 61.45 100 °F 38.0 °C
900 14.75 2350 38.51 3800 62.27 110 °F 43.0 °C
950 15.57 2400 39.33 3850 63.09 120 °F 49.0 °C
1000 16.39 2450 40.15 3900 63.91 130 °F 54.0 °C
1050 17.21 2500 40.97 3950 64.73 140 °F 60.0 °C
1100 18.03 2550 41.79 4000 65.55 150 °F 65.5 °C
1150 18.84 2600 42.61 4050 66.37 160 °F 71.0 °C
1200 19.66 2650 43.42 4100 67.19 170 °F 77.0 °C
1250 20.48 2700 44.24 4150 68.00 180 °F 82.0 °C
1300 21.30 2750 45.06 4200 68.82 190 °F 88.0 °C
1350 22.12 2800 45.88 4250 69.64 200 °F 93.0 °C
1400 22.94 2850 46.70 4300 70.46 210 °F 99.0 °C
1450 23.76 2900 47.52 4350 71.28
1500 24.58 2950 48.34 4400 72.10 C x 1.8 + 32 = °F
(F - 32) x 0.55 = °C
1550 25.40 3000 49.16 4450 72.92
Cubic Inches x 0.01639 = Liters
Liters x 61.024 = Cubic Inches

HOTSTART forced circulation preheating systems are ideal for engines ranging in
size from 10 L to the largest displacement currently in production. These systems are Forced Circulation
designed specifically for installation on a generator, compressor package, marine engine
or locomotive. HOTSTART offers forced circulation heating systems for coolant heating, Heating Systems
lube oil heating and diesel fuel heating. Combination systems are also available that heat
and circulate coolant and oil in one pre-assembled unit. Complete with all necessary
components and controls, these automated systems are available in various wattage,
voltage and phase combinations to accommodate most large industrial preheating needs.
For additional information regarding HOTSTART’s forced circulation heating systems,

please visit www.hotstart.com or contact HOTSTART and have all your questions answered
by one of our engine heating product specialists.
CMM/CLM Models Coolant-only Heating CLA/CLE Models

Systems
Voltage Range: 230 – 690 V
Heat Power: 6 – 144 kW
Coolant heating systems are designed to heat and circulate coolant throughout the engine’s cooling system to efficiently maintain
an engine at optimum starting temperatures. Maintaining jacket water temperatures ensures easy starting, reduces harmful
emissions at start-up and allows engines to go to full power without needless idling.
OSM Model OLA/OLE Models

Oil-only Heating
Systems
Voltage Range: 120 – 690 V
Heat Power: 1 – 12 kW
Oil heating systems provide uniform heating to the oil throughout the engine oil sump and external piping, enhancing engine or
compressor availability and decreasing wear and tear from cold startups.
Coolant and Oil Heating Systems Auxiliary Power Unit for Locomotive Engines
OCLA/OCLE Models
Voltage Range: 230 V, 400 V

Heat Power (Oil): 2.5 – 12 kW The HOTSTART APU allows an idling locomotive to be shut down
Heat Power (Coolant): 6 – 36 kW in cold weather at any location. This self-contained system runs off
the locomotive’s fuel supply. It will maintain water temperature at
100 °F (38 °C) above ambient and provides cab heat.

Corporate and Manufacturing Customer Services
Headquarters
5723 E Alki Ave To better serve you, HOTSTART provides a
Spokane, WA 99212 customer service department to answer all your
USA engine heating concerns and questions or to take
509.534.6171 your sales order.
sales@hotstart.com Customer Service Department:
509.536.8660
Oil & Gas Office
21732 Provincial Blvd Sales orders and requests for quotes can also be
Suite 170 faxed to our toll-free
Katy, TX 77450 FAX line.
USA Toll-free FAX line: 800.224.5550
281.600.3700
oil.gas@hotstart.com
Warranty Information
Europe Office
HOTSTART GmbH The warranty below has been drafted to comply with the Federal Law applicable to products
Am Turm 86 manufactured after December 31, 1976. This warranty gives you specific legal rights, and you
53721 Siegburg may also have other rights which vary from state to state.
Germany HOTSTART products are warranted against defects in workmanship and materials. No other
+49.2241.12734.0 express warranty, written or oral, applies. No person is authorized to give any other warranty
europe@hotstart.com or assume any liability except by written statement from an officer of HOTSTART, Inc.
Asia Pacific Office The warranty extends for twelve months from date of shipment from factory or authorized
HOTSTART Asia Pacific Ltd distributor.
2-27-15-4F, Honkomagome Products must be installed and maintained in accordance with HOTSTART, Inc. instructions.
Bunkyo-ku, Tokyo Users are responsible for the suitability of the products to their application. There is no
113-0021, Japan warranty against damage resulting from corrosion, misapplication, improper specification or
+81.3.6902.0551 other operating conditions beyond our control. Claims against carriers for damage in transit
apac@hotstart.com must be filed by the buyer.
Absolutely no material can be returned to HOTSTART, Inc. without prior factory authorization.
Upon factory authorization, return the defective part or product, freight prepaid, to:
HOTSTART, 5723 E Alki Ave, Spokane, WA 99212.
Defective items will be repaired or replaced, at our option, at no charge. Such repair or
replacements is the exclusive right of HOTSTART, Inc. HOTSTART, Inc. is not liable for labor
costs incurred in removal, reinstallation, or unauthorized repair of the product or for damage
of any type whatsoever including incidental or consequential damage. Some states do not
allow the exclusion or limitation of incidental or consequential damages, so the preceding
limitation or exclusion may not apply to you.
Exports, re-exports and imports of HOTSTART products are subject to U.S. export controls.
If you are an exporter, importer, distributor, customer or end-user, you are responsible
for complying with U.S. export controls and any local export laws in your jurisdiction.
We encourage you to seek appropriate legal advice before you export, re-export or sell
HOTSTART products.
For more information on exporting products under the U.S. Export Administration Regulations
(EAR), please visit the Bureau of Industry and Security (BIS) website: http://www.bis.doc.gov
HOTSTART, Inc.
Distributor
www.hotstart.com
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IMC-700

HEATER INSTALLATION PAGES 4 - 5

• Wiring Harnesses PAGES 38 - 40

HOTflow ® and THERMOSIPHON ENGINE HEATERS

CTM w/9.8’ (3 m) cord and Schuko plug (Euro)**

Isolation Mounting 500 – 750 CID

* - UL/C-US listed Other voltages available. Consult the factory.

4 Customer Service: 509.536.8660 hotstart.com

Customer Service: 509.536.8660 hotstart.com 5

500–2000 Watts TPS101GT8-000 8.4 TPS102GT8-000 4.2

TPS151GT8-000 12.5 TPS152GT8-000 6.3

Replacement Parts Model

Number Sensing Power Element

Sensing Unit TPS151GT8-000 LSU-8 REPS151T8 TPS-T CPS-1 11P48UU TPS-BOR

6 Customer Service: 509.536.8660 hotstart.com

TPS181GT12-001 120 1800 1 15 100 °F (38 °C) 120 °F (49 °C)

In-line thermostat options:

Replacement Parts Replacement Parts

TPS101GT12-001 120 1000 LSU-10 REPS101T12 TPS-YC1 TW2374-1

TPS181GT12-001 120 1800 LSU-10 REPS181T12 12P16H54S54X10UU TW2374-1

-001 Remote thread-in fixed temperature thermostat # Call Factory

Customer Service: 509.536.8660 hotstart.com 7

CB115100-000 CB1151XX-200 120 1500 1 12.5

CB120100-000 CB1201XX-200 120 2000 1 16.7

CB125100-000 CB1251XX-200 120 2500 1 20.8

CB Model without thermostat

Heaters with Thermostats Temperature Range Numerical

8 Customer Service: 509.536.8660 hotstart.com

Tank RTB CHART 2

Model Number: CB115110-200

Replacement 1” NPT to 0.75”

Customer Service: 509.536.8660 hotstart.com 9

CL130100-100 CL1301XX-200 120 3000 1 25.0

Temperature Range Numerical

OEM Replacement HOTSTART Caterpillar Pre-Wired

NOTE: Vertical installation ONLY

For original equipment replacement: 4.7”

10 Customer Service: 509.536.8660 hotstart.com

Temperature Model Number: CL130210-200

HOTSTART Element Common Replacement Parts Replacement Parts

Customer Service: 509.536.8660 hotstart.com 11

SB Model SB115100-000 SB1151XX-200 120 1500 1 12.5

SB122100-000 SB1221XX-200 120 2250 1 18.8

Power cord length on all models – 72” (1829 mm)

Heaters with Thermostats Temperature Range Numerical

12 Customer Service: 509.536.8660 hotstart.com

SB120100-000 SB1201XX-200 RESB1201 RHB-1-20 Tank RTB CHART 2

Model Number: SB115110-200

Customer Service: 509.536.8660 hotstart.com 13

SL Model SL130800-100 SL1308XX-200 208 3000 1 14.4

Power cord length on all models – 72” (1829mm)

Heaters with Thermostats Temperature Range Numerical

14 Customer Service: 509.536.8660 hotstart.com

SL140800-100 SL1408XX-200 RESL1408-100 RHL-WOP Tank RTL CHART 2

Adjustable 90° – 130°F

SL Model Model Number: SL130210-200

Replacement ADAPTER FITTINGS

Customer Service: 509.536.8660 hotstart.com 15

WL325800-000 WL3258XX-200 208 2500 3 6.9