IMC-700 PRODUCT CATALOG ENGINE HEATERS OIL HEATERS CONTROLS ACCESSORIES

Transcription

1 IMC-700 PRODUCT CATALOG ENGINE HEATERS OIL HEATERS CONTROLS ACCESSORIES

2 TALE OF CONTENTS HEATER INSTALLATION Page 22 (Thermosiphon) Page 5 (In-block) HOW TO SPECIFY AN ENGINE HEATER Page 54 CONVERSION CHARTS Page 54 CUSTOM PRODUCTS Call for information on: Wiring Harnesses APUs Forced Circulation Heating Systems Other Specialty Products PAGES 4-5 HOTflow Engine Heaters CTM, CSM Models PAGES 6-7 Thermosiphon Engine Heaters Weathertight Design TPS, C, CL, WL, S, SL Models PAGES 8-2 Thermosiphon Engine Heaters Hazardous Location EE Models PAGES Lube Oil Heaters (AC and DC) Industrial Immersion Heaters Thread-in and Threadless Models PAGES - 6 Remote s for Lube Oil Heaters Temperature Controls for Thermosiphon Engine Heaters Complete Control Systems PAGES 8-40 attery Warming Pads & Accessories lanket Style attery Warmers Silicone Hot Pads PAGES 42-5 In-block Heaters Electrical Cords for In-block Heaters Thermocords Flush Mount Kits and Accessories

3 SECTION HOTflow and THERMOSIPHON ENGINE HEATERS

4 HOTflow Engine Heaters CTM Model Single Phase Engine Size CID/Liter CID 0-8 L Power Supply Volts Ø Hz 20 Model Number kw Amps CTM w/8 (2.4 m) cord and NEMA plug* 50/ CTM00-N00 CTM020-N Range On Off 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) Watts CID 8-2 L 20 50/ CTM50-N00 CTM520-N F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) Meets requirements for installation on any UL 2200 listed generator CID 2 20 L CID 0 8 L / CTM250-N00 CTM2520-N CTM w/9.8 ( m) cord, without plug 50/ CTM00-A00 CTM020-A F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) CID 8 2 L 20 50/ CTM50-A00 CTM520-A F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) CID 2 20 L 20 50/ CTM250-A00 CTM2520-A F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) CTM w/9.8 ( m) cord and Schuko plug (Euro)** Isolation Mounting Kit (optional) CTM-IMK CID 0 8 L CID 8 2 L CID 2 20 L 50/ CTM020-E F (8 C) 20 F (49 C) 50/ CTM520-E F (8 C) 20 F (49 C) 50/ CTM2520-E F (8 C) 20 F (49 C) * - UL/C-US listed Other voltages available. Consult the factory. ** - CE compliant HOTSTART s HOTflow engine heater (CTM Model) features an integrated pump that combines the benefits of forced circulation with a compact design that can mount to a variety of small engine applications. Forced circulation of the coolant delivers uniform heating throughout the entire engine, extends element life and offers a significant reduction in electrical consumption. H W Height (H) Width (W ) Width2 (W 2 ) Weight lbs. 20 mm 45 mm 6 mm.6 kg W 2 4 Customer Service: hotstart.com

5 Engine Size CID/Liter 000 CID 5 0 L Power Supply Volts Ø Hz Model Number kw Amps Style CSM CSM CSM * CSM00J-5A0 CSM * CSM00A-5A0 CSM CSM A A A A Range On Off 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) HOTflow Engine Heaters CSM Model Single & Three Phase 000 Watts 000 CID L CID L CID L * CE compliant/union pump configuration Other voltages available. Consult the factory. CSM CSM * CSM0J-5A0 CSM * CSM0A-5A0 * CSM0F-5A CSM CSM CSM CSM CSM * CSM090J-5A0 CSM * CSM090A-5A0 * CSM090F-5A CSM CSM CSM CSM CSM-000 * CSM20J-5A0 CSM * CSM20A-5A0 * CSM20F-5A0 CSM CSM CSM A A A A A A 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) Meets requirements for installation on any UL 2200 listed generator. HOTSTART s HOTflow engine heater (CSM Model) features a thermostat, pump and all required controls. Forced circulation of the coolant delivers uniform heating throughout the entire engine, extends element life and offers a significant reduction in electrical consumption. The HOTflow CSM operates automatically when provided contacts are supplied with a 24 V DC signal from the engine. * union pump * union pump Style A Style H H W D W D Height (H) Width (W) Depth (D) Weight lbs. 8 mm 49 mm 242 mm 6.8 kg Height (H) Width (W) Depth (D) Weight lbs. 44 mm 49 mm 242 mm 24.5 kg * If a union pump is installed, the model s height (H) will decrease by approximately.5 (8 mm) Customer Service: hotstart.com 5

6 Thermosiphon Engine Heaters Engine Displacement Watts Model Number 20V Amps Model Number V Amps Model Number 277V Amps TPS Model Single Phase 50 CID 2.5 L 500 TPS05GT8-000 TPS05GT0-000 TPS05GT TPS052GT8-000 TPS052GT0-000 TPS052GT0-0 TPS052GT TPS057GT Watts 50 CID 5.7 L 000 TPS0GT8-000 TPS0GT0-000 TPS0GT TPS02GT8-000 TPS02GT0-000 TPS02GT0-0 TPS02GT TPS07GT CID L 500 TPS5GT8-000 TPS5GT0-000 TPS5GT TPS52GT8-000 TPS52GT0-000 TPS52GT0-0 TPS52GT TPS57GT Temperature Range ON OFF 80 F (27 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 40 F ( C) Numerical Code CID L 800 TPS8GT8-000 TPS8GT0-000 TPS8GT TPS202GT8-000 TPS202GT0-000 TPS202GT0-0 TPS202GT TPS207GT Power cord length on all models 48 (29 mm) TPS engine preheaters include a fixed setting thermostat. A single or double digit numeral at the end of the model number prefix designates the temperature range. Example: TPS0GT0-000 (see chart in left column) -0 Engine preheater features 2 meter round cord and Schuko plug - CE compliant Parts For TPS Models Model Number Sensing Unit Parts Element Tank ox Power Cord Element O-ring Tank TPS05GT8-000 TPS05GT0-000 TPS05GT2-000 TPS052GT8-000 TPS052GT0-000 TPS052GT0-0 TPS052GT2-000 TPS057GT0-000 LSU-8 LSU-0 LSU-2 LSU-8 LSU-0 LSU-0 LSU-2 LSU-0 REPS05T8 REPS05T0 REPS05T2 REPS052T8 REPS052T0 REPS052T0 REPS052T2 REPS057T0 CPS- CPS- CPS- CPS- CPS- CPS-2 CPS- CPS- P48UU P48UU P48UU 2P48UU 2P48UU 2SCH8UU 2P48UU 6H48UU TPS-OR TPS-OR TPS-OR TPS-OR TPS-OR TPS-OR TPS-OR TPS-OR Element Element O-Ring TPS0GT8-000 TPS0GT0-000 TPS0GT2-000 TPS02GT8-000 TPS02GT0-000 TPS02GT0-0 TPS02GT2-000 TPS07GT0-000 LSU-8 LSU-0 LSU-2 LSU-8 LSU-0 LSU-0 LSU-2 LSU-0 REPS0T8 REPS0T0 REPS0T2 REPS02T8 REPS02T0 REPS02T0 REPS02T2 REPS07T0 CPS- CPS- CPS- CPS- CPS- CPS-2 CPS- CPS- P48UU P48UU P48UU 2P48UU 2P48UU 2SCH8UU 2P48UU 6H48UU TPS-OR TPS-OR TPS-OR TPS-OR TPS-OR TPS-OR TPS-OR TPS-OR Sensing Unit Cord ox TPS5GT8-000 TPS5GT0-000 TPS5GT2-000 TPS52GT8-000 TPS52GT0-000 TPS52GT0-0 TPS52GT2-000 TPS57GT0-000 TPS8GT8-000 TPS8GT0-000 TPS8GT2-000 LSU-8 LSU-0 LSU-2 LSU-8 LSU-0 LSU-0 LSU-2 LSU-0 LSU-8 LSU-0 LSU-2 REPS5T8 REPS5T0 REPS5T2 REPS52T8 REPS52T0 REPS52T0 REPS52T2 REPS57T0 REPS8T8 REPS8T0 REPS8T2 CPS- CPS- CPS- CPS- CPS- CPS-2 CPS- CPS- CPS- CPS- CPS- P48UU P48UU P48UU 2P48UU 2P48UU 2SCH8UU 2P48UU 6H48UU 2P6H48UU 2P6H48UU 2P6H48UU TPS-OR TPS-OR TPS-OR TPS-OR TPS-OR TPS-OR TPS-OR TPS-OR TPS-OR TPS-OR TPS-OR TPS202GT8-000 TPS202GT0-000 TPS202GT0-0 TPS202GT2-000 TPS207GT0-000 LSU-8 LSU-0 LSU-0 LSU-2 LSU-0 REPS202T8 REPS202T0 REPS202T0 REPS202T2 REPS207T0 CPS- CPS- CPS-2 CPS- CPS- 2P48UU 2P48UU 2SCH8UU 2P48UU 6H48UU TPS-OR TPS-OR TPS-OR TPS-OR TPS-OR 6 Customer Service: hotstart.com

7 Engine Displacement 50 CID 2.5 L 50 CID 5.7 L CID L Model Number Volts Watts Phase Amps TPS05GT2-00 TPS05GT2-A00 TPS052GT2-00 TPS052GT2-A00 TPS0GT2-00 TPS0GT2-A00 TPS02GT2-00 TPS02GT2-A00 TPS5GT2-00 TPS5GT2-A00 TPS52GT2-00 TPS52GT2-A Range On Off 00 F (8 C) 20 F (49 C) ADJUSTALE 00 F (8 C) 20 F (49 C) ADJUSTALE 00 F (8 C) 20 F (49 C) ADJUSTALE 00 F (8 C) 20 F (49 C) ADJUSTALE 00 F (8 C) 20 F (49 C) ADJUSTALE 00 F (8 C) 20 F (49 C) ADJUSTALE Thermosiphon Engine Heaters TPS Model w/in-line adjustable and remote thread-in fixed thermostat. Single Phase 500 Watts CID L TPS8GT2-00 TPS8GT2-A00 TPS202GT2-00 TPS202GT2-A Remote thread-in fixed temperature thermostat F (8 C) 20 F (49 C) ADJUSTALE 00 F (8 C) 20 F (49 C) ADJUSTALE Adjustable 90 0 F (2 54 C) On differential -20 F (-7 C) Remote Adjustable Assembly Part Number TFTA-5/8H In-line thermostat options: Power Y-cord OUTLET HOSEAR I.D (4X) Holes For Mounting rackets.5 8mm Adjustable Assembly mm mm mm Well In-Line Adjustable INLET HOSEAR I.D mm Remote Thread-in Fixed Temperature Model Number TPS05GT2-00 TPS05GT2-A00 TPS052GT2-00 TPS052GT2-A00 TPS0GT2-00 TPS0GT2-A00 TPS02GT2-00 TPS02GT2-A00 TPS5GT2-00 TPS5GT2-A00 TPS52GT2-00 TPS52GT2-A00 Volts Watts Sensing Unit LSU-0 RSU90-0 LSU-0 RSU90-0 LSU-0 RSU90-0 LSU-0 RSU90-0 LSU-0 RSU90-0 LSU-0 RSU90-0 Element REPS05T2 REPS05T2 REPS052T2 REPS052T2 REPS0T2 REPS0T2 REPS02T2 REPS02T2 REPS5T2 REPS5T2 REPS52T2 REPS52T2 Parts Power Y-cord TPS-YC # TPS-YC2 # TPS-YC # TPS-YC2 # TPS-YC # TPS-YC2 # Well TW274- # TW274- # TW274- # TW274- # TW274- # TW274- # Parts For TPS Model w/in-line adjustable and remote thread-in fixed thermostat. Single Phase Common replacement parts for all TPS engine preheaters: Tank ox Element O-ring TPS8GT2-00 TPS8GT2-A00 TPS202GT2-00 TPS202GT2-A LSU-0 RSU90-0 LSU-0 RSU90-0 REPS8T2 REPS8T2 REPS202T2 REPS202T2 2P6H54S54X0UU # TPS-YC2 # TW274- # TW274- # See table on page 6-00 Remote thread-in fixed temperature thermostat # Call Factory Customer Service: hotstart.com 7

8 Thermosiphon Engine Heaters Engine Displacement Model Number without Model Number with see chart Volts Watts Phase Amps C Model Weathertight Single Phase Watts CID L C C C C C C C5XX-200 C58XX-200 C52XX-200 C57XX-200 C5XX-200 C54XX CID L C-000 C C C-000 C C20XX-200 CXX-200 C202XX-200 C20XX-200 C204XX CID 9.8.L C C C C C C C25XX-200 C258XX-200 C252XX-200 C257XX-200 C25XX-200 C254XX C Model without thermostat CHART C Model with thermostat Heaters with s To specify temperature range of thermostat, insert numerical code from chart in place of the XX in model number. Example: Desired Temp. Range: F Model Number: C5XX-200 Order as: C Temperature Range ON 80 F (27 C) 00 F (8 C) 20 F (49 C) OFF 00 F (8 C) 20 F (49 C) 40 F ( C) Adjustable 90 0 F (2 54 C) Numerical Code A C Model 6.2 4mm mm OUTLET, NPT FEMALE 4. 04mm 4. 09mm INLET, NPT FEMALE mm mm OUTLET, NPT FEMALE 5. 29mm 5.2 2mm INLET, NPT FEMALE 8 Customer Service: hotstart.com

9 Model Number without Model Number with see chart 2 Element Common Parts available for all listed heaters Parts C C C C C C C5XX-200 C58XX-200 C52XX-200 C57XX-200 C5XX-200 C54XX-200 REC5 REC58 REC52 REC57 REC5 REC54 High Limit Control Check Valve Element O-ring HLC-65 RV-M TMM-OR For thermosiphon engine heaters C Model C-000 C C C-000 C C20XX-200 CXX-200 C202XX-200 C20XX-200 C204XX-200 REC20 REC REC202 REC20 REC204 Tank ox Mounting rackets RT RTC RTMM CHART 2 Heaters with s Temperature Range ON OFF Sensing Unit C C C C C C C25XX-200 C258XX-200 C252XX-200 C257XX-200 C25XX-200 C254XX-200 REC25 REC258 REC252 REC257 REC25 REC F (27 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 40 F ( C) Adjustable 90 0 F (2 54 C) Example: FSU8 FSU0 FSU2 FSU90-0 Model Number: C T-Stat : FSU0 C Model with thermostat assembly Element O-Ring ADAPTER FITTINGS Tank For the use of 0.75 or ID heater hose, hose barb adapters are available. See below. Temperature Sensing Unit Mounting rackets High Limit Control ox H- NPT to hose barb adapter. Installs in NPT female inlet or outlet of the heater. Element H-/4 NPT to 0.75 hose barb adapter. Installs in NPT female inlet or outlet of the heater. Check Valve Customer Service: hotstart.com 9

10 Thermosiphon Engine Heaters Engine Displacement Model Number without Model Number with see chart Volts Watts Phase Amps CL Model Weathertight Single Phase CID. 6.4 L CL CL CL CL CL CL CL0XX-200 CL08XX-200 CL02XX-200 CL07XX-200 CL0XX-200 CL04XX Watts CID L CL CL CL CL CL CL408XX-200 CL402XX-200 CL407XX-200 CL40XX-200 CL404XX CID L CL CL CL CL CL CL508XX-200 CL502XX-200 CL507XX-200 CL50XX-200 CL504XX CL Model without thermostat CHART Heaters with s To specify temperature range of thermostat, insert numerical code from chart in place of the XX in model number. Example: Desired Temp. Range: F Model Number: CL02XX-200 Order as: CL CL Model INLET, NPT FEMALE mm ADJUSTALE OUTLET, NPT FEMALE mm 5.25 mm CL Model with thermostat Temperature Range ON 80 F (27 C) 00 F (8 C) 20 F (49 C) OFF 00 F (8 C) 20 F (49 C) 40 F ( C) Adjustable 90 0 F (2 54 C) Numerical Code A INLET, NPT FEMALE mm ADJUSTALE OUTLET, NPT FEMALE mm mm OEM Weathertight Single Phase Watts HOTSTART Model Number Caterpillar Model Number Volts Pre-Wired at assembly CL0DA E / CL40EA2-000 / 4000 CLEA E-6248 ( ) / 00 CLCA E V circuits 00 Watts Phase Amps 20 V V V V V V 25.0 per circuit NOTE: Vertical installation ONLY For original equipment replacement: Two 5 stainless steel clamps are included to mount heater to existing bracket. For new installations: U-bolt mounting brackets available. Order kit number: FK mm OUTLET NPT NIPPLE 4.7 9mm mm Vertical Mount OEM replacement INLET, NPT NIPPLE 0 Customer Service: hotstart.com

11 Model Number without CL CL CL CL CL CL CL CL CL CL CL CL CL CL CL CL CL Model with thermostat assembly Temperature Sensing Unit Model Number with see chart 2 CL0XX-200 CL08XX-200 CL02XX-200 CL07XX-200 CL0XX-200 CL04XX-200 CL408XX-200 CL402XX-200 CL407XX-200 CL40XX-200 CL404XX-200 CL508XX-200 CL502XX-200 CL507XX-200 CL50XX-200 CL504XX-200 Mounting rackets Element RECL0-00 RECL08-00 RECL02-00 RECL07-00 RECL0-00 RECL04-00 RECL RECL RECL RECL40-00 RECL RECL RECL RECL RECL50-00 RECL Tank Element O-Ring Common Parts available for all listed heaters High Limit Control Check Valve Element O-ring Tank ox Mounting rackets High Limit Control HLC-65 RV-M TML-OR RTL RTCL-00 FK7 ox Parts For thermosiphon engine heaters CL Model CHART 2 Heaters with s Temperature Range ON 80 F (27 C) 00 F (8 C) 20 F (49 C) OFF 00 F (8 C) 20 F (49 C) 40 F ( C) Adjustable 90 0 F (2 54 C) Example: Sensing Unit FSU8 FSU0 FSU2 Model Number: CL T-Stat : FSU0 FSU90-0 Element Check Valve HOTSTART Model Number Element Common Parts available for all OEM replacement heaters Parts CL0DA2-000 CL40EA2-000 CLEA2-000 RECL0D RECL40E RECLC Element O-ring Tank AMT7020-A2 TML-OR RTCSM For thermosiphon engine heaters OEM CLCA2-000 RECL40E ox RTCL-00 CL OEM Element O-Ring Tank ox Element CL Model with thermostat Customer Service: hotstart.com

12 Thermosiphon Engine Heaters Engine Displacement Model Number without Model Number with see chart Volts Watts Phase Amps S Model with power cord Weathertight Single Phase CID L S S S S S5XX-200 S58XX-200 S52XX-200 S57XX Watts CID L S-000 S S S20XX-200 SXX-200 S202XX CID 9.8. L S S S S S22XX-200 S258XX-200 S252XX-200 S257XX Power cord length on all models 72 (829 mm) All V and 277 V models come with cord only - no plug. CHART S Model with power cord no thermostat Heaters with s To specify temperature range of thermostat, insert numerical code from chart in place of the XX in model number. Example: Desired Temp. Range: F Model Number: S5XX-200 Order as: S Temperature Range ON 80 F (27 C) 00 F (8 C) 20 F (49 C) OFF 00 F (8 C) 20 F (49 C) 40 F ( C) Adjustable 90 0 F (2 54 C) Numerical Code A S Model S Model with thermostat and power cord mm mm OUTLET, NPT FEMALE 4. 04mm 4. 09mm INLET, NPT FEMALE mm mm OUTLET, NPT FEMALE 5. 29mm 5.2 2mm INLET, NPT FEMALE 2 Customer Service: hotstart.com

13 Model Number without Model Number with see chart 2 Element Power Cord Common Parts available for all listed heaters Parts S S S S S5XX-200 S58XX-200 S52XX-200 S57XX-200 RES5 RES58 RES52 RES57 RH--5 RH-WOP RH-2-5 RH-WOP High Limit Control Check Valve Element O-ring HLC-65 RV-M TMM-OR For thermosiphon engine heaters S Model S-000 S S S20XX-200 SXX-200 S202XX-200 RES20 RES RES202 RH--20 RH-WOP RH-2-5 Tank ox RT RTS CHART 2 Heaters with s S S22XX-200 RES22 RH--20 Mounting rackets RTMM Temperature Range ON OFF Sensing Unit S S S S258XX-200 S252XX-200 S257XX-200 RES258 RES252 RES257 RH-WOP RH-2-5 RH-WOP 80 F (27 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 40 F ( C) FSU8 FSU0 FSU2 Adjustable 90-0 F (2-54 C) FSU90-0 Example: S Model with thermostat assembly Tank Element O-Ring Model Number: S T-Stat : FSU0 Temperature Sensing Unit Mounting rackets High Limit Control ox ADAPTER FITTINGS Element For the use of 0.75 or ID heater hose, hose barb adapters are available. See below. Check Valve H- NPT to hose barb adapter. Installs in NPT female inlet or outlet of the heater. H-/4 NPT to 0.75 hose barb adapter. Installs in NPT female inlet or outlet of the heater. Customer Service: hotstart.com

14 Thermosiphon Engine Heaters Engine Displacement Model Number without Model Number with see chart Volts Watts Phase Amps SL Model with power cord Weathertight Single Phase CID. 6.4 L SL SL SL SL08XX-200 SL02XX-200 SL07XX Watts CID L SL SL SL SL408XX-200 SL402XX-200 SL407XX Power cord length on all models 72 (829mm) All V and 277 V models come with cord only - no plug. CHART SL Model with power cord no thermostat Heaters with s To specify temperature range of thermostat, insert numerical code from chart in place of the XX in model number. Example: Desired Temp. Range: F Model Number: SL02XX-200 Order as: SL Temperature Range ON 80 F (27 C) 00 F (8 C) 20 F (49 C) OFF 00 F (8 C) 20 F (49 C) 40 F ( C) Adjustable 90 0 F (2 54 C) Numerical Code A SL Model SL Model with thermostat and power cord mm ADJUSTALE OUTLET, NPT FEMALE 5.25 mm mm INLET, NPT FEMALE mm ADJUSTALE OUTLET, NPT FEMALE mm mm INLET, NPT FEMALE 4 Customer Service: hotstart.com

15 Model Number without Model Number with see chart 2 Element Power Cord Common Parts available for all listed heaters Parts SL SL SL SL08XX-200 SL02XX-200 SL07XX-200 RESL08-00 RESL02-00 RESL07-00 RHL-WOP RHL-2-5 RHL-WOP High Limit Control Check Valve HLC-65 RV-M For thermosiphon engine heaters SL Model Element O-ring TML-OR SL SL SL SL408XX-200 SL402XX-200 SL407XX-200 RESL RESL RESL RHL-WOP RHL-2-20 RHL-WOP Tank ox Mounting rackets RTL RTCL-00 FK7 CHART 2 Heaters with s Temperature Range ON OFF Sensing Unit 80 F (27 C) 00 F (8 C) 20 F (49 C) 00 F (8 C) 20 F (49 C) 40 F ( C) FSU8 FSU0 FSU2 Adjustable 90 0 F (2 54 C) FSU90-0 SL Model with thermostat assembly High Limit Control Example: Model Number: SL T-Stat : FSU0 Element O-Ring Temperature Sensing Unit Mounting rackets Tank Element ox ADAPTER FITTINGS For the use of 0.75 or ID heater hose, hose barb adapters are available. See below. H- NPT to hose barb adapter. Installs in NPT female inlet or outlet of the heater. H-/4 NPT to 0.75 hose barb adapter. Installs in NPT female inlet or outlet of the heater. Check Valve Customer Service: hotstart.com 5

16 Thermosiphon Engine Heaters Engine Displacement Model Number without Model Number with see chart Volts Watts Phase Amps WL Series Weathertight Three Phase CID 9.8. L WL WL WL25A WL WL WL258XX-200 WL252XX-200 WL25AXX-200 WL254XX-200 WL255XX Watts CID L WL WL WL40A WL WL WL408XX-200 WL402XX-200 WL40AXX-200 WL404XX-200 WL405XX CID L WL WL WL50A WL WL WL508XX-200 WL502XX-200 WL50AXX-200 WL504XX-200 WL505XX CHART WL Model without thermostat Heaters with s To specify temperature range of thermostat, insert numerical code from chart in place of the XX in model number. Example: Desired Temp. Range: F Model Number: WL252XX-200 Order as: WL Temperature Range ON 80 F (27 C) 00 F (8 C) 20 F (49 C) OFF 00 F (8 C) 20 F (49 C) 40 F ( C) Adjustable 90 0 F (2 54 C) Numerical Code A All phase heaters with thermostat must use a control box. See Control Systems page 4. WL Model with thermostat WL Model mm OUTLET, NPT ADJUSTALE FEMALE 5.25 mm mm INLET, NPT FEMALE mm ADJUSTALE OUTLET, NPT FEMALE mm mm INLET, NPT FEMALE 6 Customer Service: hotstart.com

17 Model Number without Model Number with see chart 2 Element Common Parts available for all listed heaters Parts WL WL WL25A WL WL WL258XX-200 WL252XX-200 WL25AXX-200 WL254XX-200 WL255XX-200 REWL258 REWL252 REWL25A REWL254 REWL255 High Limit Control Check Valve Element O-ring HLC-65 RV-M TML-OR For thermosiphon engine heaters WL Series WL WL WL40A WL WL WL WL WL50A WL WL WL408XX-200 WL402XX-200 WL40AXX-200 WL404XX-200 WL405XX-200 WL508XX-200 WL502XX-200 WL50AXX-200 WL504XX-200 WL505XX-200 REWL408 REWL402 REWL40A REWL404 REWL405 REWL508 REWL502 REWL50A REWL504 REWL505 Tank Mounting rackets RTL FK7 CHART 2 Heaters with s Temperature Range ON 80 F (27 C) 00 F (8 C) 20 F (49 C) OFF 00 F (8 C) 20 F (49 C) 40 F ( C) Adjustable 90 0 F (2 54 C) Sensing Unit FSU8 FSU0 FSU2 FSU90-0 Example: Model Number: WL T-Stat : FSU0 WL Model with thermostat assembly High Limit Control Mounting rackets Tank Element Element O-Ring ADAPTER FITTINGS For the use of 0.75 or ID heater hose, hose barb adapters are available. See below. H- H-/4 NPT to hose barb adapter. Installs in NPT female inlet or outlet of the heater. NPT to 0.75 hose barb adapter. Installs in NPT female inlet or outlet of the heater. Check Valve Customer Service: hotstart.com 7

18 Thermosiphon Engine Heaters Engine Displacement Model Number without Model Number with Volts Watts Phase Amp EE Model Hazardous Location Single Phase 500cid or less 8.2L or less EE EE EE EE EE EE Watts 500-0cid L EE-000 EE EE EE EE0-000 EE cid L EE EE EE EE EE EE EE Model without thermostat cid L EE EE EE EE EE EE cid L EE EE EE EE EE EE cid L EE EE EE Model with thermostat Heaters with s EE Models are only available with a fixed setting temperature sensor. Temperature Range ON OFF Numerical Code 00 F (8 C) 20 F (49 C) 0 All heaters over V with a thermostat must use a control box. See Control Systems page 4. EE Model mm ADJUSTALE OUTLET, NPT FEMALE 5. 5mm 5. 5mm INLET, NPT FEMALE mm ADJUSTALE OUTLET, NPT FEMALE mm 5. 5mm 8 Customer Service: hotstart.com

19 Model Number without Model Number with Element Common Parts available for all listed heaters Parts EE EE EE EE EE EE EE EE REEE5 REEE58 REEE52 E054E-50NA-00 Check Valve Flange RV-M RF-L For thermosiphon engine heaters EE Model Flange O-ring TML-OR EE-000 EE EE EE EE EE EE EE EE0-000 EE EE EE EE EE REEE20 REEE REEE202 E0204E-50NA-00 REEE258 REEE252 E0254E-C0NA-00 Tank MC-HL cable Mounting rackets RTL PRP FK7 Heaters with s Temperature Range ON OFF Sensing Unit 00 F (8 C) 20 F (49 C) RSU0 Example: EE EE EE EE EE EE REEE08 REEE02 E004E-50NA-00 Model Number: EE T-Stat : RSU0 EE EE EE EE EE EE REEE408 REEE402 E0404E-50NA-00 EE EE E0504E-C0NA-00 EE Model with thermostat assembly Flange & O-Ring ADAPTER FITTINGS Tank Check Valve Mounting rackets Element For the use of 0.75 or ID heater hose, hose barb adapters are available. See below. H- NPT to hose barb adapter. Installs in NPT female inlet or outlet of the heater. MC-HL Cable H-/4 NPT to 0.75 hose barb adapter. Installs in NPT female inlet or outlet of the heater. Customer Service: hotstart.com 9

20 Thermosiphon Engine Heaters Engine Displacement Model Number without Model Number with Volts Watts Phase Amp EE Model Hazardous Location Three Phase 500cid or less 8.2L or less EE EE EE EE EE EE Watts 500-0cid L EE EE EE EE0-000 EE EE cid L EE EE EE EE EE EE EE Model without thermostat cid L EE EE EE EE EE EE cid L EE EE EE EE EE EE EE Model with thermostat cid L EE EE EE EE EE EE Heaters with s EE Models are only available with a fixed setting temperature sensor. Temperature Range ON OFF Numerical Code 00 F (8 C) 20 F (49 C) 0 All phase heaters with thermostat must use a control box. See Control Systems page 4. EE Model mm ADJUSTALE OUTLET, NPT FEMALE 5. 5mm 5. 5mm INLET, NPT FEMALE mm ADJUSTALE OUTLET, NPT FEMALE mm 5. 5mm 20 Customer Service: hotstart.com

21 Model Number without Model Number with Element Common Parts available for all listed heaters Parts EE EE EE EE EE EE E058E-5NA-00 E052E-5NA-00 E054E-5NA-00 Check Valve Flange RV-M RF-L For thermosiphon engine heaters EE Model EE EE EE EE0-000 EE EE E0E-25NA-00 E0202E-25NA-00 E0204E-25NA-00 Flange O-ring Tank TML-OR RTL Heaters with s EE EE EE EE EE EE E0258E-0NA-00 E0252E-0NA-00 E0254E-0NA-00 MC-HL cable Mounting rackets PRP FK7 Temperature Range ON OFF Sensing Unit 00 F (8 C) 20 F (49 C) RSU0 EE EE EE EE EE EE E008E-0NA-00 E002E-0NA-00 E004E-0NA-00 Example: Model Number: EE T-Stat : RSU0 EE EE EE EE EE EE E0408E-50NA-00 E0402E-50NA-00 E0404E-50NA-00 EE EE EE EE EE EE E0508E-50NA-00 E0502E-50NA-00 E0504E-50NA-00 EE Model with thermostat assembly Flange & O-Ring ADAPTER FITTINGS For the use of 0.75 or ID heater hose, hose barb adapters are available. See below. Tank Mounting rackets Element H- NPT to hose barb adapter. Installs in NPT female inlet or outlet of the heater. Check Valve H-/4 NPT to 0.75 hose barb adapter. Installs in NPT female inlet or outlet of the heater. MC-HL Cable Customer Service: hotstart.com 2

22 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 over 000 CID (5L), HOTSTART recommends using a HOTflow heater. Please refer to pages 4-5 for heater selection. Prior to heater installation, inspect the coolant supply. When mixing coolant, only use deionized or distilled water and low-silicate antifreeze. Refer to your engine s manufacturer recommendations. Do not exceed % antifreeze to 40% water ratio. Never add unmixed water and antifreeze to an engine. Do not add anti-leak or other coolant additives. PREPARING Drain and flush cooling system to remove any debris present in the engine s cooling system. Select return port. The return port will allow heated coolant to return to the engine. Select supply port. The supply port will allow coolant to flow from the engine to the heater. Select fittings. Use the following table to determine the proper port fitting size for your heater: C/CL/S/SL watts /2 inch NPT C/CL/S/SL watts /4 inch NPT WL/EE watts /4 inch NPT Select hoses. Use the following table to determine the minimum hose inner diameter for your heater: C/CL/S/SL watts /4 inch C/CL/S/SL watts inch WL/EE watts inch HOTSTART recommends installing valves to isolate the heating system in case of service. To minimize flow restriction, select full-flow ball isolation valves. MOUNTING Select a heater mounting position directly below the return port and at least 6 inches (5 cm) below the lowest point of the engine s water jacket. Mount heater using the supplied mounting brackets and fasteners. PLUMING Install isolation valves to port fittings. Route and install return hose. The return hose should continuously rise from the heater to the return port. Route and install supply hose. The supply hose should continuously descend from the supply port to the heater. Refill cooling system with coolant. To prevent air pockets, refill coolant with return hose removed. Start engine. Allow engine to run until engine thermostat opens, purging air from cooling system. Engine must be run to eliminate air from heating system before energizing heater. WIRING Connect heater to an appropriately rated power source. Ensure power source is grounded and in accordance with local and national electrical codes. If necessary, install control box: If your heater is single-phase and rated up to volts, your heater may be powered directly without the use of a control relay or contactor. If your heater is three-phase or is single-phase and rated for over volts, the heater thermostats must be used in a control circuit with a contactor for switching the main power to the heating elements. 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 (5 cm) below the lowest point of the water jacket. 22 Customer Service: hotstart.com

23 SECTION 2 LUE OIL AND INDUSTRIAL IMMERSION HEATERS

24 Oil Heaters Oil Heaters up to 277 V AC meet recognized CSA standards for safety or performance. 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 level at all times. See page 25 for remote thermostat part numbers. *NOTE: If heating gear oil (medium weight viscosity), HOTSTART recommends using low watt density heaters. Oil Capacity Weathertight Heater Only Weathertight With Hazardous Location Heater Only Volts Watts Amps Watts/Sq Inch To specify temperature range of thermostat, insert code from chart in place of the XX in model number. 2 qt. (2L) or Less /8 N.P.T. THREAD WITH A 2 /8 (54mm) PROE LENGTH OW OW /2 N.P.T. THREAD WITH A 4 (0mm) PROE LENGTH Example: Desired Temp. Range F Model Number: OW22XX-000 Order as: OW2-000 Temperature Range ON F (6 C) 80 F (27 C) 00 F (8 C) OFF 80 F (27 C) 00 F (8 C) 20 F (49 C) See p.25 for remote thermostat assembly part numbers. Code qt L - 5 gal..8-9l 5-5 gal. 9-57L - 5 gal..8-9l 5-5 gal. 9-57L OW OW OW22XX-000 OW222XX-000 OE OE /4 N.P.T. THREAD WITH A 5 (27mm) PROE LENGTH OW OW OW OW OW OW45XX-000 OW452XX-000 OW40XX-000 OW408XX-000 OW402XX-000 OE OE OE OE OE N.P.T. THREAD WITH A 5 /4 (mm) PROE LENGTH OW OW OW OW OW OW65XX-000 OW652XX-000 OWXX-000 OW8XX-000 OW2XX-000 OE OE OE OE OE OE OE OE * 4.6* * 0.7* Oil heater with Y-cord and remote thermostat 5-0 gal L OW OW OW OW OW650XX-000 OW6508XX-000 OW6502XX-000 OW6507XX-000 OE OE OE OE OE OE OE Weathertight models are furnished with a 4 (.2m) oil- and heat-resistant power cord without plug. Hazardous Location models are furnished with 8 (457mm) of lead wire for connection to the power leads in an approved splice box DC Oil Heaters 2 V and 24 V When used with a thermostat control, all DC oil heaters must use a DC relay. _ 2 or 24 V DC + Magnetic Contactors C C Oil Capacity 2 qt. 2.0L or Less 2-6 qt L -5 gal..8-9l /2 NPT with Volts Watts 4 (0mm) Probe Length OW /4 NPT with 4 7/8 (24mm) Probe Length OW OW NPT with 5 /8 (6mm) Probe Length Amps 6.. Watts Per Square Inch /2 4.7* WSI /4 7.* WSI OW WSI OW OW OW OW /4 4.6* WSI 0.7* WSI DIT C COIL Oil Heater 5-5 gal. 9-57L OW OW OW /4 29. WSI 2.4 WSI 2 Vdc/24 Vdc CONTROL OXES 5-0 gal. 57-L OW WSI 25 Amps Maximum 2V 24V JMC0DC-2V JMC0DC-24V 2 V DC and 24 V DC oil heaters can be powered directly from the battery, but will drain the battery very rapidly unless charged by an alternator or generator. 24 Customer Service: hotstart.com

25 Weathertight Heater only Hazardous Location Heater only mm 5.25 mm Probe Length.00 NPT.00 Dia. 25mm mm 5.25 mm Probe Length.00 NPT.00 Dia. 25.5mm mm mm Probe Length /4 NPT mm mm mm Probe Length /4 NPT mm mm mm Probe Length /2 NPT 0.50 Dia. mm 8.0 2mm mm Probe Length /2 NPT 0.50 Dia. mm REMOTE THERMOSTATS for OIL HEATERS Switch Capacity Weathertight DIT68 DIT80 DIT02 DIT24 Hazardous Location DIT68EP DIT80EP DIT02EP DIT24EP Temprature Range ON OFF F (6 C) 80 F (27 C) 80 F (27 C) 00 F (8 C) 00 F (8 C) 20 F (49 C) 20 F (49 C) 40 F ( C) Sensing Unit LSU-6 LSU-8 LSU-0 LSU-2 Thread Size /2 NPT /2 NPT /2 NPT /2 NPT 20 V - 5amp V - 0amp V - 0amp 277 V - 0amp 2 V DC 24 V DC Pilot Duty } Only (m) 6- HPN cord.75 86mm /2 NPT.625 4mm Probe Length 0. Dia. 5mm.25 8mm mm /2 NPT.625 4mm Probe Length 0. Dia. 5mm Weathertight Hazardous Location Customer Service: hotstart.com 25

26 Industrial Immersion Heaters 2 Screw Plug Available with fixed or adjustable thermostat. Models for larger capacities than shown are available. Call factory. Oil Capacity HIGH LIMIT THERMOSTAT CONTROL SETTING On F (6 C) Off 80 F (27 C) On 80 F (27 C) Off 00 F (8 C) On 00 F (8 C) Off 20 F (49 C) SINGLE PHASE 2 N.P.T. WITH A 2 (05mm) PROE LENGTH Volts Watts Amps Watts/ Sq. In Gallons -70L E00W-56A-00 E008W-56A-00 E002W-56A-00 E007W-56A-00 E00W-58A-00 E008W-58A-00 E002W-58A-00 E007W-58A-00 E00W-5A-00 E008W-5A-00 E002W-5A-00 E007W-5A C US 45 - Gallons L E05W-56A-00 E058W-56A-00 E052W-56A-00 E057W-56A-00 E05W-58A-00 E058W-58A-00 E052W-58A-00 E057W-58A-00 E05W-5A-00 E058W-5A-00 E052W-5A-00 E057W-5A Weathertight Model NEMA Gallons -70L THREE PHASE 2 N.P.T. WITH A 2 (05mm) PROE LENGTH E008W-06A-00 E002W-06A-00 E00W-06A-00 E004W-06A-00 E008W-08A-00 E002W-08A-00 E00W-08A-00 E004W-08A-00 E008W-0A-00 E002W-0A-00 E00W-0A-00 E004W-0A Gallons L E058W-56A-00 E052W-56A-00 E05W-56A-00 E054W-56A-00 E058W-58A-00 E052W-58A-00 E05W-58A-00 E054W-58A-00 E058W-5A-00 E052W-5A-00 E05W-5A-00 E054W-5A C US SINGLE PHASE 2 N.P.T. WITH A 8 (457mm) PROE LENGTH (LVD only) Hazardous Location Model NEMA 4 & 7-90 Gallons 227-4L E020W-56A-00 E0W-56A-00 E0202W-56A-00 E0207W-56A-00 E020W-56A-00 E0204W-56A-00 E020W-58A-00 E0W-58A-00 E0202W-58A-00 E0207W-58A-00 E020W-58A-00 E0204W-58A-00 E020W-5A-00 E0W-5A-00 E0202W-5A-00 E0207W-5A-00 E020W-5A-00 E0204W-5A THREE PHASE 2 N.P.T. WITH A 8 (457mm) PROE LENGTH - 90 Gallons 227-4L E0W-56A-00 E0202W-56A-00 E020W-56A-00 E0204W-56A-00 E0W-58A-00 E0202W-58A-00 E020W-58A-00 E0204W-58A-00 E0W-5A-00 E0202W-5A-00 E020W-5A-00 E0204W-5A 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. 26 Customer Service: hotstart.com

27 HOTSTART immersion heaters include a fixed-setting, built-in thermostat and are available with an adjustable thermostat. Weathertight Model NEMA 4 Hazardous Location Model NEMA 4 & 7 Industrial Immersion Heaters 2 Screw Plug 4. 09mm 2 or 8 05mm or 457mm mm 2 or 8 05mm or 457mm.6 9mm 4.4 2mm Fixed Assembly TEMPERATURE RANGE ON OFF F (6 C) 80 F (27 C) 00 F (8 C) 80 F (27 C) 00 F (8 C) 20 F (49 C) ELECTRICAL RATING 5 Amps at 20 Vac 0 Amps at Vac 0 Amps at 277 Vac Sensor Control CONTROL HLC-6 HLC-8 HLC-0 Adjustable Assembly Adjustable Control TEMPERATURE RANGE OFF F (2 99 C) CONTROL AMT70-20 Nominal thermal differential is 8 F (- C) ELECTRICAL RATING 0 Amps at 25 Vac 0 Amps at Vac 0 Amps at 277 Vac 20 Amps at Vac NOTES: On applications where level of fluid is subject to change, a liquid level switch mounted a minimum of 4 (76 02mm) above element is recommended. Liquid level switch is not included with heater. All 80 V and V heaters must be used in conjunction with contactor and control transformer. All three phase models must be used with a contactor. See page 4. Higher or lower temperature ranges are available. Consult HOTSTART. Customer Service: hotstart.com 27

28 V-Clamp Immersion Heaters Threadless Design Available with fixed or adjustable thermostat. Models for larger capacities than shown are available. Call factory. Oil Capacity HIGH LIMIT THERMOSTAT CONTROL SETTING On F (6 C) Off 80 F (27 C) On 80 F (27 C) Off 00 F (8 C) On 00 F (8 C) Off 20 F (49 C) SINGLE PHASE WITH A 2 (05mm) PROE LENGTH Volts Watts Amps Watts/ Sq. In Gallons -70L E00W-56V-00 E008W-56V-00 E002W-56V-00 E007W-56V-00 E00W-58V-00 E008W-58V-00 E002W-58V-00 E007W-58V-00 E00W-5V-00 E008W-5V-00 E002W-5V-00 E007W-5V C US 45 - Gallons L E05W-56V-00 E058W-56V-00 E052W-56V-00 E057W-56V-00 E05W-58V-00 E058W-58V-00 E052W-58V-00 E057W-58V-00 E05W-5V-00 E058W-5V-00 E052W-5V-00 E057W-5V Weathertight Model NEMA Gallons -70L E008W-06V-00 E002W-06V-00 E00W-06V-00 E004W-06V-00 THREE PHASE WITH A 2 (05mm) PROE LENGTH E008W-08V-00 E002W-08V-00 E00W-08V-00 E004W-08V-00 E008W-0V-00 E002W-0V-00 E00W-0V-00 E004W-0V Gallons L E058W-56V-00 E052W-56V-00 E05W-56V-00 E054W-56V-00 E058W-58V-00 E052W-58V-00 E05W-58V-00 E054W-58V-00 E058W-5V-00 E052W-5V-00 E05W-5V-00 E054W-5V C US SINGLE PHASE WITH A 8 (457mm) PROE LENGTH (LVD only) Hazardous Location Model NEMA 4 & 7-90 Gallons 227-4L E020W-56V-00 E0W-56V-00 E0202W-56V-00 E0207W-56V-00 E020W-56V-00 E0204W-56V-00 E020W-58V-00 E0W-58V-00 E0202W-58V-00 E0207W-58V-00 E020W-58V-00 E0204W-58V-00 E020W-5V-00 E0W-5V-00 E0202W-5V-00 E0207W-5V-00 E020W-5V-00 E0204W-5V THREE PHASE WITH A 8 (457mm) PROE LENGTH - 90 Gallons 227-4L E0W-56V-00 E0202W-56V-00 E020W-56V-00 E0204W-56V-00 E0W-58V-00 E0202W-58V-00 E020W-58V-00 E0204W-58V-00 E0W-5V-00 E0202W-5V-00 E020W-5V-00 E0204W-5V 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. 28 Customer Service: hotstart.com

29 HOTSTART immersion heaters include a fixed-setting, built-in thermostat and are available with an adjustable thermostat. Weathertight Model NEMA 4 Hazardous Location Model NEMA 4 & 7 V-Clamp Immersion Heaters Threadless Design 2 or 8 05mm or 457mm.8 97mm 5. 76mm 2 or 8 05mm or 457mm Element assembly includes O-ring only. Installation kit sold separately. V-CLAMP INSTALL KIT Weldable Adapter Part Number Parts Included O-Ring V-Clamp O-Ring Weldable Adapter V-Clamp VC-SK Steel weldable adapter V-Clamp O-Ring.6 9mm 4.4 2mm Fixed Assembly TEMPERATURE RANGE ON OFF F (6 C) 80 F (27 C) 00 F (8 C) 80 F (27 C) 00 F (8 C) 20 F (49 C) ELECTRICAL RATING 5 Amps at 20 Vac 0 Amps at Vac 0 Amps at 277 Vac Sensor Control CONTROL HLC-6 HLC-8 HLC-0 Adjustable Assembly Adjustable Control TEMPERATURE RANGE OFF F (2 99 C) CONTROL AMT70-20 Nominal thermal differential is 8 F (- C) ELECTRICAL RATING 0 Amps at 25 Vac 0 Amps at Vac 0 Amps at 277 Vac 20 Amps at Vac NOTES: On applications where level of fluid is subject to change, a liquid level switch mounted a minimum of 4 (76 02mm) above element is recommended. Liquid level switch is not included with heater. All 80 V and V heaters must be used in conjunction with contactor and control transformer. All three phase heaters must be used with a contactor. See page 4. Higher or lower temperature ranges are available. Consult HOTSTART. Customer Service: hotstart.com 29

30 SECTION TEMPERATURE CONTROLS and CONTROL SYSTEMS

31 Temperature Controls Remote s for Weathertight and Hazardous Location Oil Heaters (see p.24 for model numbers) REMOTE THERMOSTATS for OIL HEATERS Switch Capacity Weathertight Hazardous Location Temprature Range ON OFF Sensing Unit Thread Size 20 V - 5amp V - 0amp DIT68 DIT80 DIT02 DIT24 DIT68EP DIT80EP DIT02EP DIT24EP F (6 C) 80 F (27 C) 80 F (27 C) 00 F (8 C) 00 F (8 C) 20 F (49 C) 20 F (49 C) 40 F ( C) LSU-6 LSU-8 LSU-0 LSU-2 /2 NPT /2 NPT /2 NPT /2 NPT V - 0amp 277 V - 0amp 2 V DC 24 V DC Pilot Duty } Only.75 86mm.625 4mm Probe Length mm.625 4mm Probe Length 0. Dia. 5mm.25 8mm 0. Dia. 5mm (m) 6- HPN cord /2 NPT /2 NPT Weathertight Hazardous Location Remote Adjustable for TPS Thermosiphon Engine Heater (see p.7 for model numbers) 5/8 H x 5/8 H mm 4- HPN 4 (.2m) Part Number Adjustable Range Temperature Setting Sensing Unit TFTA-5/8H Adjustable 90 0 F (2 54 C) FSU mm mm Part number does not include Y cord Power Y-cord OUTLET HOSEAR I.D HOSEAR Adjustable Assembly mm mm In-Line Adjustable INLET HOSEAR I.D. Customer Support: hotstart.com

32 Temperature Controls When using a thermostat above rated capacity or on phase applications, select the proper control box with transformer and contactor as shown on page mm.8 46mm 4. 0mm 4X /2 CONDUIT KNOCKOUT NPT (FEMALE) NPT (MALE) Part Number TFTC8-200 TFTC0-200 TFTC2-200 NPT female x NPT male CONDUIT TYPE ENCLOSURE On Temperature Setting Off 80 F (27 C) 00 F (8 C) 00 F (8 C) 20 F (49 C) 20 F (49 C) 40 F ( C) Maximum Capacity Ratings 20/ V 277V V 25amp 22amp 2.5amp 25amp 22amp 2.5amp 25amp 22amp 2.5amp mm TFTCA-200 Adjustable 90 0 F (2 54 C) 25amp 22amp 2.5amp.6 92mm 4X /2 CONDUIT KNOCKOUT NPT male x NPT male CONDUIT TYPE ENCLOSURE.8 46mm 4. 0mm NPT (MALE) NPT (MALE) Part Number TFTC8-220 TFTC0-220 TFTC2-220 Temperature Setting On Off 80 F (27 C) 00 F (8 C) 00 F (8 C) 20 F (49 C) 20 F (49 C) 40 F ( C) Maximum Capacity Ratings 20/ V 277V V 25amp 22amp 2.5amp 25amp 22amp 2.5amp 25amp 22amp 2.5amp mm TFTCA-220 Adjustable 90 0 F (2 54 C) 25amp 22amp 2.5amp.6 92mm 4X /2 CONDUIT KNOCKOUT hose barb x NPT male CONDUIT TYPE ENCLOSURE.8 46mm H 4. 0mm NPT (MALE) Part Number Temperature Setting On Off TFTC8-80 F (27 C) 00 F (8 C) TFTC0-00 F (8 C) 20 F (49 C) TFTC2-20 F (49 C) 40 F ( C) Maximum Capacity Ratings 20/ V 277V V 25amp 22amp 2.5amp 25amp 22amp 2.5amp 25amp 22amp 2.5amp mm TFTCA- Adjustable 90 0 F (2 54 C) 25amp 22amp 2.5amp.0 76mm mm /2" NPT Conduit Opening Part Number HAZARDOUS LOCATION CONDUIT TYPE ENCLOSURE On Temperature Setting Off Maximum Capacity Ratings 20/ V 277V V.0 " NPT Inlet TFT0ER 00 F (8 C) 20 F (49 C) 25amp 22amp 2.5amp.25 2mm mm 2 Customer Service: hotstart.com

33 When using a thermostat above rated capacity or on phase applications, select the proper control box with transformer and contactor as shown on page 4. Temperature Controls NPT female x NPT male CORD CONNECTED.6 92mm 4X /2 CONDUIT KNOCKOUT Part Number TFT8-200 TFT0-200 TFT2-200 On Temperature Setting Off 80 F (27 C) 00 F (8 C) 00 F (8 C) 20 F (49 C) 20 F (49 C) 40 F ( C) Maximum Capacity Ratings 20/ V 5amp 5amp 5amp 277V 5amp 5amp 5amp NPT (FEMALE) 5.4 7mm NPT (MALE) TFTA-200 Adjustable 90 0 F (2 54 C) 5amp 5amp.8 46mm mm NPT male x NPT male CORD CONNECTED.6 92mm 4X /2 CONDUIT KNOCKOUT Part Number TFT8-220 TFT0-220 TFT2-220 Temperature Setting On Off 80 F (27 C) 00 F (8 C) 00 F (8 C) 20 F (49 C) 20 F (49 C) 40 F ( C) Maximum Capacity Ratings 20/ V 5amp 5amp 5amp 277V 5amp 5amp 5amp 5.4 7mm NPT (MALE) NPT (MALE) TFTA-220 Adjustable 90 0 F (2 54 C) 5amp 5amp.8 46mm mm hose barb x NPT male CORD CONNECTED.6 92mm 4X /2 CONDUIT KNOCKOUT Part Number TFT8- TFT0- TFT2- Temperature Setting On Off 80 F (27 C) 00 F (8 C) 00 F (8 C) 20 F (49 C) 20 F (49 C) 40 F ( C) Maximum Capacity Ratings 20/ V 5amp 5amp 5amp 277V 5amp 5amp 5amp 5.4 7mm H NPT (MALE) TFTA- Adjustable 90 0 F (2 54 C) 5amp 5amp.8 46mm mm Part Number AT6525 REMOTE ADJUSTALE With 5 (.5m) Capillary Probe Adjustable Range Temperature Setting F (8-2 C) (Open or Off Setting) Differential 4 F (2.2 C) (Close or On Setting) Maximum Capacity Ratings 20// 277V V V 25amp 22amp 5amp 6.4 6mm mm LO.0 76mm.9 48mm mm mm Dia. 25 ATW Aluminum Well for AT6525 /2 NPT Customer Service: hotstart.com 95

34 Control Systems 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 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, 2 & IP66. CONTROL SYSTEMS CONTROL SYSTEMS featuring AUTOMATIC SHUTDOWN DEVICES With 24 V DC Relay Amps Volts Heater, per application 2 Heaters, 2 s per application 0A Max 0A Max 0A Max 0A Max 0A Max 0A Max JC-00 JC8-00 JC2-00 JCA-00 JC4-00 JC5-00 JC2-00 JC28-00 JC22-00 JC2A-00 JC24-00 JC25-00 Model JC4-00 See wiring schematic page 5 Model JC24-00 See wiring schematic page 5 All HOTSTART heaters with thermostat, operating on three phase current (at any voltage), require the use of a control system with a -pole contactor. All HOTSTART heaters with thermostat, operating over V (single or three phase) require a control system to reduce the primary voltage to 20 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. 4 Customer Service: hotstart.com

35 Wiring Schematic for JC4-00 USER SUPPLIED CIRCUIT REAKER L MAIN L2 POWER IN L Control Systems EQUIPMENT GROUND MUST E GROUNDED H4 CONTROL TRANSFORMER V PRIMARY C H MAGNETIC CONTACTORS K X 20V 50VA X2 C2 HEATING ELEMENT A USER SUPPLIED 24VDC SIGNAL A2 K2 2 N/C Model JC4-00 CONTACTOR COIL K 4 2 USER SUPPLIED THERMOSTAT To control one V heater at maximum 0 amps on manual start engine. Wiring Schematic for JC24-00 MAIN POWER IN USER SUPPLIED CIRCUIT REAKER L L2 L EQUIPMENT GROUND MUST E GROUNDED H4 X CONTROL TRANSFORMER V PRIMARY 20V 50VA C H X2 MAGNETIC CONTACTORS C2 K C K2 A USER SUPPLIED 24VDC SIGNAL A2 C4 K 2 N/C HEATING ELEMENT HEATING ELEMENT Model JC24-00 CONTACTOR COIL 4 K 2 5 K2 2 USER SUPPLIED THERMOSTAT CONTACTOR COIL To control two V heaters at maximum 0 amps on automatic start engines. Customer Service: hotstart.com 5

36 Power Distribution ox POWER DISTRIUTION OX Use to simplify wiring on equipment when a variety of heaters and controls are required. All models have ten, 25 Amp terminal blocks. Power Distribution oxes are rated NEMA 4 and IP66/67 PD-000 Part Number Number of Openings *ox comes assembled with 4 strain relief connectors. For additional connectors, order part# A PD-000 8* 4.5 4mm.0 76mm 0 AMP MAX A mm OIL PRESSURE SWITCH For automatic cut-off of heaters when engine starts. Maximum Current Capacity: 20 V/ V/ V/277 V 25 Amps 80 V/ V/575 V 5 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. Part Number Enclosure Type NEMA PS252 PS252R PS252WT PS252EP Dry Locations Dry Locations (Reverse Action) Wet Locations Hazardous Locations 6 Customer Service: hotstart.com

37 SECTION 4 ATTERY PADS/WRAPS

38 attery Heating Pads Model Number Volts Watts Amps Nominal Dimensions A attery Size Style K505 K505-S K505-D (24mm) 2.75 (24mm) 2.75 (24mm) 8.25 (20mm) 8.25 (20mm) 8.25 (20mm) 4D 4D 4D A C K755 K755-S K755-D (495mm) 9.5 (495mm) 9.5 (495mm) 0.5 (267mm) 0.5 (267mm) 0.5 (267mm) 8D 8D 8D A C attery heater not recommended for nickel cadmium batteries. When batteries are placed in an insulated battery box, a thermostat is recommended to sense battery box temperature to prevent overheating the battery. Standard Pad for Single attery A K752 K752-S K752-D Typical Connection - 2 atteries on Each Side of Vehicle Left Side attery ox K755-D K755-D (495mm) 9.5 (495mm) 9.5 (495mm) Right Side attery ox K755-D 0.5 (267mm) 0.5 (267mm) 0.5 (267mm) K755-S 8D 8D 8D A C Style A EC-6 Ground Y-T68 PC-6 6 HPN.8m Accessories For Multiple attery Heating Special Pads for Multiple atteries mm 6- HPN mm Style Style C 6- HPN A A EXTENSION CORDS Part Number Length EC-2 2 (0.7m) EC-4 4 (.2m) EC-6 6 (.8m) EC-8 8 (2.4m) 2 (0.7m) 4 (.2m) 6 (.8m) 8 (2.4m) POWER SUPPLY CORDS Part Number Length Volts PC- (m) 20 PC-2 (m) PC-6 6 (.8m) 20 PC-62 6 (.8m) (m) 6 (.8m) 6- HPN THERMOSTAT & Y CORD ASSEMLY Part Temperature Control Number On Off Y-T68 F (6 C) 80 F (27 C).2 5mm CORD 6- HPN.5 4mm mm 8 Customer Service: hotstart.com

39 attery Group* UL RECOGNIZED ATTERY THERMAL WRAP WITH THERMOSTAT range: F - 80 F (6 C - 27 C) Model Number Volts Watts Wrap Length 72 Power Cord** Strap attery Thermal Wrap 22NF W05006S-000 W052006S (762 mm) 0 (762 mm) PC-6 PC-62 W-S-55 24, 24F, 24H, 24R, 24T, 25, 27, 27H, 4, 4R, 5, 75, 78, GC2 W06806S-000 W062806S (965 mm) 8 (965 mm) PC-6 PC-62 W-S-55 0H, W0846S-000 W08246S (68 mm) 46 (68 mm) PC-6 PC-62 W-S-55 2E W05406S-000 W025406S (72 mm) 54 (72 mm) PC-6 PC-62 W-S-80 4D, 6D W6206S-000 W26206S (575 mm) 62 (575 mm) PC-6 PC-62 W-S-80 8D W67006S-000 W627006S (778 mm) 70 (778 mm) PC-6 PC-62 W-S-80 A EURO ATTERY THERMAL WRAP FOR SCHUKO PLUG WITH THERMOSTAT range: F - 80 F (6 C - 27 C) attery Group* Model Number Volts Watts Wrap Length 72 Power Cord** Strap 22NF W052006S (762 mm) PC-62E W-S-55 24, 24F, 24H, 24R, 24T, 25, 27, 27H, 4, 4R, 5, 75, 78, GC2 W062806S (965 mm) PC-62E W-S-55 0H, W08246S (68 mm) PC-62E W-S " (0 25 cm) MAX. attery wrap installation, showing battery (A), cord (), strap (C) and buckle (D). Maximum overlap is 0 inches (25 cm). C D 2E W025406S (72 mm) PC-62E W-S-80 4D, 6D W26206S (575 mm) PC-62E W-S-80 8D W627006S (778 mm) PC-62E W-S-80 * Not all battery groups listed. For wrap sizing, consult the factory. ** Power cord sold separately. For other cord lengths, consult the factory. attery wrap comes with a 9 (229 mm) pigtail. PC-6 and PC-62 have a NEMA plug. PC-62E has a Schuko plug. Please order the necessary power cord to complete your wrap assembly. UL Recognized 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. will eliminate battery damage caused by overheating and acid spill. Adjustable strap included for securing wrap around the battery. For optimized heating, properly overlap the wrap and have the thermostat stay in contact with the battery. Maxium allowable overlap is 0 (25 cm). If placed inside a case or box, HOTSTART recommends a minimum clearance of.5 (8 mm) between battery and enclosure wall. Euro battery wraps not UL Recognized. Customer Service: hotstart.com 9

40 attery Thermal Wrap ATTERY THERMAL WRAP NO THERMOSTAT Model Number Volts Watts Length KW (7 mm) KW (94 mm) KW (829 mm) Prolong the life of your battery with HOTSTART thermal battery wraps. Wraps without a thermostart are not UL Recognized. Durable, fire-retardant vinyl cover that resists oils and acids. All standard battery pads and battery wraps come with 6 (.8 m) grounded cord and plug. Fast, easy installation. oosts battery cranking power as much as 75%. Silicone Pad Heaters Versatile and Easy to Install 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. 20 V models are assembled with a standard 6 (.8m) HPN cord and plug. V models include 6 (.8m) HPN cord without plug. Model Number Volts Watts Dimensions Not for use on batteries AF005 AF x 5 (02mm x 27mm) AF505 AF x 5 (02mm x 27mm) AF2505 AF x 6 (27mm x 52mm) AF4005 AF x 8 (52mm x 20mm) Application Guidline 00 Watt 50 Watt 250 Watt 400 Watt Engine oil pan 2-5 quarts.9-4.7l 5-8 quarts L 2-5 gallons L 5-8 gallons L Diesel Tank 5-7 gallons L 7-0 gallons L 0-20 gallons L 20-0 gallons L Hydraulic Tank - 5 gallons L 5-0 gallons L 0-20 gallons L 20-0 gallons L Water Tank up - 2 gallons up - 7.5L 2-4 gallons L 4-7 gallons L 7-0 gallons L CAUTION: Do not use pads with higher than recommended wattage for specific oil capacities. For use on metal surfaces only. 40 Customer Service: hotstart.com

41 SECTION 5 IN-LOCK HEATERS and ACCESSORIES 4

42 In-block Heaters In-block heaters are complete with 2-wire w/ground 6 (.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 20V V Required 670T & I 685T & I 68LT, T & I (844 CID) ALL 4 CYL 90 ALL 6 CYL 590 AC-0 CATV-5 CU-75FP CU-0FP CU-5FP AC-02 CATV-52 CU-752FP CU-02FP CU-52FP Allis Chalmers Replaces thread-in plug on the oil cooler at rear of the engine on right side. Not all of the engines have this opening. Case/IH Agricultural Inserts in any of the core plugs on right side of engine. ALL 6 CYL 80 CUC-5FP CUC-52FP 500 Inserts in the core plug at right rear of engine block. C-0 C-2 C-9 Non ACERT C-5 Non ACERT C-6 Non ACERT TF2-000 TF CATV-5 CATV Caterpillar Replaces the threaded plug in the oil cooler bonnet on the right side of engine. C-9: Replaces NPT plug in the right rear of engine block. C-5, C-6: Replaces the threaded plug in the back of the oil cooler. YES C7 ACERT 26 FP0-00 FP5-00 FP02-00 FP Replaces the 44mm core plug on right side of engine just below the turbo charger. YES C7 ACERT rear port TL0-000 TL Replaces the threaded -/6 (.0625 ) plug in the rear of engine block. C9 ACERT CATV-5 CATV Replace NPT plug in the right rear of engine block. C ACERT C ACERT TF5-008 TF Replace any -5/6 (.25 ) plug in the rear of the oil cooler on right side of engine. Check Exhaust Routing C5 ACERT w/o breaksaver TF5-009 TF Replace -/6 (.875 ) plug in rear of oil cooler on right side of engine. C5 ACERT with breaksaver TF5-008 TF Replace any -5/6 (.25 ) plug in the oil cooler on right side of engine. C ACERT C 2007 ACERT C ACERT TF5-02 TF Replace any -/6 (.875 ) plug in rear of oil cooler on right side of engine. 674 CAT-5 CAT Replace the -/2 (.5 ) plug on right side of engine. 69 & D4 CATC-5 CATC Replaces the water jacket access plate on left side of engine. 69T & 69TA CATC-5-S CATC-52-S 500 Replaces the water jacket access plate on left side of engine. 0.5L L FP5-00 FP Replaces 40mm core plug on the front left side of engine. 42 Customer Service: hotstart.com

43 In-block heaters are complete with 2-wire w/ground 6 (.8m) HPN cord and plug. For cord replacements or Y Thermocord energy saver, please reference page 52. In-block Heaters C US Engine Model Part Number Part Number Watts Application Information Heat Shield Photo 20V V Required Caterpillar Continued L FP5-00 FP Replaces 40mm core plug on the front left side of the engine L FP5-00 FP Replaces 50mm core plug located at rear of head. 044.L PF5-00 PF Replaces the plate in oil cooler case on left side of engine L PF5-000 PF Replaces 5mm core plug located at rear of engine, left side L L PER-75FP PER-0FP PER-752FP PER-02FP Mounts in the -/4 (.25 ) core plug opening on left side of engine. 054C PER-75FP PER-752FP L PER-5FP PER-52FP 500 Mounts in -/4 (.25 ) core plug at right rear of engine with element oriented in the 2 O clock position. Mounts in the -/2 (.5 ) core plug on right side of engine. 4 6 FP0-00 FP5-00 FP02-00 FP Replaces the 44mm core plug on right side of engine just below the turbocharger. YES 76 0.L through 995 DD8L-0 CAT-205 TF5-00 DD8L-02 CAT-202 TF Replaces the /4 (0.75 ) threaded plug on the right side of engine just below the head L 996 and later TF2-000 TF Replaces the threaded plug in the oil cooler bonnet on right side of engine. YES L TF2-000 TF Replaces the threaded plug in oil cooler bonnet on right side of engine. YES 204 all 00 series CATX-75 CATX-0 CATX-752 CATX Replaces 44mm core plug on right rear side of engine. 2 heaters with a single cord Recommended aftermarket installation CATX-2-75-Y JD/4-0IN JD-0IN JD/4-5IN JD-5IN CATX Y JD/4-02IN JD-02IN JD/4-52IN JD-52IN 500 total Use on industrial engines when clear access is available. Replaces any core plug - one on each side of engine. Replaces any of the /4 (0.75 ) or plugs on the water transfer casting (right front of engine). /4 use JD/4 use JD DD8L-0 CAT-205 TF5-00 DD8L-02 CAT-202 TF Replaces the /4 (0.75 ) plug on left side of engine. 406C/E 4.6L AC-0 CATV-5 AC-02 CATV Replaces threaded plug in the rear of the oil cooler bonnet on right side of engine. Customer Service: hotstart.com 4

44 In-block Heaters In-block heaters are complete with 2-wire w/ground 6 (.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 20V V Required 406 & 408 except 998 ADEM 2 AC-0 CATV-5 AC-02 CATV-52 Caterpillar Continued Replaces threaded plug in the rear of the oil cooler bonnet on right side of engine. 406E 998 ADEM 2 engines only TF5-002 TF Replaces the threaded plug that points downward on the top of the rear of the oil cooler bonnet. YES 406E ADEM and ADEM engines AC-0 CATV-5 AC-02 CATV Replaces threaded plug in the rear of the oil cooler bonnet on right side of engine L AC-0 CATV-5 AC-02 CATV Replaces threaded plug in the rear of the oil cooler bonnet on right side of engine. Cummins 6 Cylinder Engines: H, NT, NH, N Family 74 CID, 855 CID, 927 CID, N4. Cummins engines are often referred to by their horsepower rating i.e. 50 Cummins 2. Cummins engines are often referred to as ig Cam, ig Cam2,, 4, full flow cooling, etc. All refer to engines of 855 CID Size listed below Group I Flat plate design CUN-5 CUN Flat plate design when the /2 NPT opening is used CUN-5H CUN-52H bolt flat plate on the right side of the engine. May use either the forward or rear opening depending on clearance. When an external oil cooler is used.. Group II Note: When a 4 bolt flat plate element design is encountered, remove the next two bolts on the casting, remove the whole casting, and replace the casting and element with either CNT-5/CNT-52 OR CNT590/CNT5290 When connection is /2 rubber hose Engines produced Aug. 975 thru June 982 CNT-5-90 CNT bolt, flat plate design with an elbow that will rotate degrees to connect with any hose or casting. Uses an O ring for the /4 water tube connection Engines produced prior to August 75 For industrial engines with hole pattern reversed CNT-5 CNT CUN-5REV CUN-52REV bolt, flat plate design with an elbow that will rotate degrees to connect with any hose or casting. Group III Six bolt flat plate on the right side of engine block. Group IV 998 and later N4 Industrial PF5-002 PF Six bolt flat plate on the right side of engine block. 44 Customer Service: hotstart.com

45 In-block heaters are complete with 2-wire w/ground 6 (.8m) HPN cord and plug. For cord replacements or Y Thermocord energy saver, please reference page 52. In-block Heaters C US Engine Model Part Number Part Number Watts Application Information Heat Shield Photo 20V V Required Cummins Continued Cummins A 4 cyl & 6 cyl CUA-0F CUA-02F 000 Inserts in any of the core plugs on right side of engine. Element points down. ISC/QSC 8.L ISL/QSL 9.0L DD8L-0 TF DD8L-02 TF Replaces /4 (0.75 ) NPT plug in right front side of engine. L0, M ISM 2007 CUL-5 CUL Inserts in the forward opening of the heater casting on the right rear of engine block. QS.9L, 5.9L IS 5.9 TF TF Replaces /4 (0.75 ) NPT plug in the front of the oil cooler casting. ISM/QSM.0L Flat Plate Design PF5-00 PF Right rear. Replaces plate. ISX, QSX Signature 0 Pre 2007 PF5-004 PF Mounts in the oval shaped plate on the right side of engine block. 4T.9L CU-75FP CU-0FP CU-752FP CU-02FP Replaces 57.8mm core plug on right side of engine. Check Exhaust Routing 6T 5.9L CU-75FP CU-0FP CU-5FP CU-752FP CU-02FP CU-52FP Replaces 57.8mm core plug on right side of engine. Check Exhaust Routing 6CT 8.L CUC-5FP CUC-52FP 500 Replaces 57.8mm core plug on right rear side of engine. Detroit Diesel SERIES 0 4 cylinder Phaser engines PER-75FP PER-0FP PER-752FP PER-02FP Mounts in the -/4 (.25 ) core plug opening on either side of engine. SERIES 0 6 cylinder Phaser engines PER-5FP PER-52FP 500 Mounts in the -/4 (.25 ) core plug on right side of engine. SERIES 0 DD8L-0 TF DD8L-02 TF Mounts in the /4 (0.75 ) NPT opening in engine block. SERIES 40 all versions PER-75FP INTA-2 FR5-00 PER-752FP INTA-22 FR Mounts in the core plug opening on right side of engine. Customer Service: hotstart.com 45

46 In-block Heaters In-block heaters are complete with 2-wire w/ground 6 (.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 20V V Required Detroit Diesel continued SERIES 50 SERIES Pre 2007 AC-0 CATV-5 AC-02 CATV Mounts in the NPT opening in either water pick up pipe (up to 99) or in the NPT opening on the oil cooler housing after 99. Yes on 99 and later SERIES 55 PF5-000 PF Mounts in the triangle plate on the side of engine block. -5, 4-5, -7, 4-7 with water cooled air compressor DD-75-S DD-752-S 750 Mounts in the oval shaped plate on engine block. Check clearance. -5, 4-5, -7, 4-7 without water cooled air compressor DD-75 DD Mounts in the oval shaped plate on engine block. Check clearance. 6-7 with water cooled air compressor DD-5-S DD-52-S 500 Mounts in the oval shaped plate on engine block. Check clearance. 6-7 without water cooled air compressor DD-5 DD Mounts in the oval shaped plate on engine block. Check clearance. 8.2 L V-8 Diesel DD8L-0 TF DD8L-02 TF Threads into the /4 (0.75 ) NPT opening on engine block. 6V-5 with water cooled air compressor DD6V-75-S DD6V-752-S 750 Mounts in the oval shaped plate on engine block. Check clearance. 6V-5 without water cooled air compressor DD6V-75 DD6V Mounts in the oval shaped plate on engine block. Check clearance. 6V7 & 8V7 Alternate location AC-0 CATV-5 AC-02 CATV Threads into NPT plug in the front face of engine block. 6V-7 & 8V-7 6V-92 & 8V-92 except GMC General models DDV-5 DDV Mounts in the square plate on engine block. 6V92 & 8V92 alternate location - threads into oil cooler DD8L-0 TF DD8L-02 TF Threads into the /4 (0.75 ) NPT opening in the oil cooler housing. Note - not all engines have this opening. F4L9 F6L9 FL92 FL9 F6L9 0 SERIES oil cooled engines OLT2255 and A22M48M (adapter) n/a 50 Deutz Use adapter kit to mount the 22mm heater in the 48mm opening. 46 Customer Service: hotstart.com

47 In-block heaters are complete with 2-wire w/ground 6 (.8m) HPN cord and plug. For cord replacements or Y Thermocord energy saver, please reference page 52. In-block Heaters C US Engine Model Part Number Part Number Watts Application Information Heat Shield Photo 20V V Required Deutz continued 02 4 & 6 cyl 0 4 cyl PF PF2-00 PF PF Mounts in the oval shaped plate opening on the oil cooler casting. 0 6 cyl PF2-00 PF PF22-00 PF Mounts in the oval shaped plate opening on the top of the oil cooler & 8 cyl TL5-004 TL Replaces 0mm plug in water elbow on front of engine & 6 cyl without electric fuel injection PF PF Replace oval shaped plate on the top of the oil cooler. Ford 7.L V-8 diesels from 994 on TF DD8L-0 TF DD8L Mounts in the /4 (0.75 ) NPT plug in the engine s block. Hino.8L, 5.8L, 6.0L, 6.4L, 6.7L, H06C-T, H07C-, W04C-T, W06E DD8L-0 TF DD8L-02 TF Threads into /4 (0.75 ) NPT opening in engine block. YES Isuzu 4D 6HE 6D 6SA 6G TF40-00 NONE 400 Replaces NPT plug on left rear of engine. Iveco NEF 4cyl NEF 6 cyl PF75-00 PF Mount in front opening on right side of engine block. John Deere With /4 plug in the back of the block JD/4-0IN JD/4-5IN JD/4-02IN JD/4-52IN /4 (0.75 ) NPT opening in the rear face of engine block. Check Exhaust Routing With plug in the back of the block JD-0IN JD-5IN JD-02IN JD-52IN NPT opening in the rear face of engine block. With -5/8 opening on the side of the water jacket JDS-0 JDS-5 JDS-02 JDS /8 (.625 ) threaded opening on the side of the block in the water distribution channel. Customer Service: hotstart.com 47

48 In-block Heaters In-block heaters are complete with 2-wire w/ground 6 (.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 20V V Required John Deere continued 5 (0.5L) 625 (2.5L) AC-0 CATV-5 AC-02 CATV NPT opening in the oil cooler casting. Komatsu L0 (0L) M(L) CUL-5 CUL Inserts in the forward opening of the heater casting on the right rear of engine block. SA6D25 MA-5 MA Threads into the core plug opening in engine block., L, M Series D905 V205 D005 V05 D05 V505 D000 V4000 D200 V400 DH905 VH205 DH005 VH05 TF40-00 NONE 400 Kubota Replaces NPT plug on left front of engine. Mack Mid liner E MS200 & MS250 MAM-0 MAM Mounts in rear face of block. Mid liner E5 MS00 MAM-5 MAM Mounts in the oil cooler bonnet. E6 engines smooth bore 98 and later E6 engines threaded core plug opening Pre-98 END 465, 7, EN48, 504, 707, 67, 675, 676 (957 through 98) E7 Engines Except E-Tech water pump mount MAS-5 MAS MA-5 MA PF5-00 PF0-000 PF52-00 PF Replaces -/4 (.75 ) core plug on side of engine. Mounts in any threaded core plug opening. Mounts in the plate in either the front or rear face of the block in the water jacket passage. For 2002 engine mounts in rear face of block. E9, ENDT865, 866 and 000 series V8 engines Use two heaters DD8L-0 DD8L-02 total Threads into the /4 (0.75 ) NPT opening on each side of engine block. 48 Customer Service: hotstart.com

49 In-block heaters are complete with 2-wire w/ground 6 (.8m) HPN cord and plug. For cord replacements or Y Thermocord energy saver, please reference page 52. In-block Heaters C US Engine Model Part Number Part Number Watts Application Information Heat Shield Photo 20V V Required MAN D2840 D2842 D2848 D2866 D2876 PF2-00 PF PF5-006 PF Replace oval shaped plate in lower water pipe on right side of engine. Replace bolt plate on left side of engine. May require adapter if bolt opening is not available on engine. Consult customer service. Massey Ferguson cylinder 4 cylinder 6 cylinder PER-75FP PER-0FP PER-752FP PER-02FP Mounts in any of the -/4 (.25 ) core plug openings in the engine. YES ME904 ME906 ME924 ME925 PF0-00 PF Mercedes enz Replaces mm core plug on right rear of engine. Navistar/International V800 (796 CID) AC-0 CATV-5 AC-02 CATV Threads into a NPT opening in the oil cooler bonnet. INLINE 6 CYLINDER all series 2,, 44, 46, 466 & 50 INTA-2 INTA-0 INTA-22 INTA Replaces third or fourth core plug on left side of engine. Element should point toward O clock position. 7.L & T and later TF DD8L-0 TF DD8L Mounts in the /4 (0.75 ) NPT plug in the engine s block. 9.0L V8 diesel INT9-0F INT9-02F 000 Mounts in a core plug. Oliver ALL EXCEPT 265, 65 & 900 TF DD8L-0 TF DD8L Threads into a /4 (0.75 ) NPT opening in the block. Onan See Cummins A Series Perkins PER-75FP PER-0FP PER-752FP PER-02FP Mounts in the -/4 (.25 ) core plug opening on right side of engine FP5-00 FP Replaces core plug on left front of engine. Customer Service: hotstart.com 49

50 In-block Heaters In-block heaters are complete with 2-wire w/ground 6 (.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 20V V Required Perkins continued 700 Series FP5-00 FP Replaces 50mm core plug located at rear of head. 800 Series PF5-00 PF Mounts in oval shaped plate on the left front of the block. 004 (right side) FR FR0-000 PER-5FP FR FR PER-52FP Mounts in the -/2 (.5 ) core plug opening on right side of engine. 004 (left side) PER-75FP PER-0FP PER-752FP PER-02FP Mounts in the -/4 (.25 ) core plug opening on left side of engine. 006 (6 Cyl) A & PER-5FP PER-52FP 500 Mounts in the -/2 (.5 ) core plug on right side of engine. 0C FR WOC FR WOC 50 Replaces -/4 (.25 ) core plug on right rear of engine. Element should point towards O clock position. 04 (4 Cyl) C & D PER-75FP PER-0FP PER-752FP PER-02FP Mounts in -/4 (.25 ) core plug opening on right side of engine. Volvo D9 PF5-007 PF Replaces oval shaped plate on right side of engine. D2C Prior to Serial # PF5-005 PF Replaces oval shaped plate on right side of engine. YES D2C After Serial # PF2-002 PF Replaces oval shaped plate on right side of engine. YES TD, TD6, TD70, TD7, TD00, TD0, VE0, TD20, TD2 VT6-0 VT Mounts into threaded opening on left side of engine. Yanmar T72HLE 4TN82E D4T YYDXL4.4 TF40-00 NONE 400 NPT No replacement cord available. 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. 50 Customer Service: hotstart.com

51 Instructions for: In-block heaters Please refer to specific instructions that accompany heater. In-block Heater Installation THREADED PLUG TYPE HEATERS A. Drain the cooling system.. Remove the recommended core plug. (See instructions with heater) C. Apply teflon tape to pipe threads or grease to O-ring. D. Thread heater into engine. Please follow these steps to ensure proper operation of your HOTSTART in-block heater.. Align cord with pins on the heater and press the cord into the heater. Place clamp around cord & heater. DO NOT PLUG IN HEATER YET! 2. Route the cord, keeping away from hot or moving surfaces.. 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. lock should feel warm near heater. PLATE TYPE HEATERS A. Drain the cooling system.. Remove the recommended plate. (See instructions with heater) C. Clean the gasket area. D. Apply gasket sealant to plate and engine surfaces. E. Insert heater into engine. Tighten bolts. Please follow these steps to ensure proper operation of your HOTSTART in-block heater.. Align cord with pins on the heater and press the cord into the heater. Place clamp around cord & heater. DO NOT PLUG IN HEATER YET! 2. Route the cord, keeping away from hot or moving surfaces.. 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. lock should feel warm near heater. FREEZE (CORE) PLUG TYPE HEATERS A. Drain the cooling system.. Remove the recommended core plug. (See instructions with heater) C. Clean, smooth and dry core plug opening. D. If retaining ring style, apply a light coat of grease to the O- ring and core plug opening. If press-in style, apply a light coat of hightemperature, high-strength retaining compound (Loctite 640 recommended). 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. Please follow these steps to ensure proper operation of your HOTSTART in-block heater.. Align cord with pins on the heater and press the cord into the heater. Place clamp around cord & heater. DO NOT PLUG IN HEATER YET! 2. Route the cord, keeping away from hot or moving surfaces.. 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. lock should feel warm near heater. Customer Service: hotstart.com 5

52 Cords & s For use with In-block Heaters Cord Length Plug Style 20 Volt Volt STYLE C US 6.8m IM6-IN IM6-2IN 5amp, 20V.4m IM-IN IM-2IN Heat Shield 6 4.8m Cord Length IM6-IN IM6-2IN Plug Style 20 Volt Volt 5amp, V Fits most competitor s applications. STYLE 2 C US HS 6.8m 2 PR72T 2PR72T 5amp, 20V.4m 2 PR2T 2PR2T Use when exhaust manifold or turbo come close to heater termination m 2 PR92T 2PR92T 5amp, V IM6-IN PR72T NOTE: When ordering in-block heater and thermocord, place suffix WOC (which stands for without cord) after the heater model number to save cost as the standard 6 (.8m) heater cord is replaced by the Thermocord harness. Thermocord for In-block Heaters Part No. Volts Thread Temp Range Size TC / F (8 49 C) TC / F (49 C) TC / F (8 49 C) TC / F (49 C) 4.2m C ft. m US ft. m TC / F (27 8 C) TC0-866 / F (27 8 C) Heater shown for illustration purposes only 52 Customer Service: hotstart.com

53 Model Number 20 Volt Model Number Volt Flush Mount Kits for In-block Heaters Cord Length Plug Style IM6-IN-FM IM6-2IN-FM 6 (.8.m) 2 IM-IN-FM IM-2IN-FM (.4m) 2 IM6-IN-FM IM6-2IN-FM 6 (4.8m) 2 Kits include: PR- style cord (shown on page 52), recessed male receptacle and hinged flip cover. C US Flush Mount Kits & Accessories. 79mm.0 76mm Flush Mount Kits for Thermosiphon Engine Heaters Model Number Volts Amps For Heater with Wattage of: FM to 800 FM to 000 FM to 2250 Kits include: Recessed male receptacle with 6 (.8m) cord (no female connectors), hinged flip cover and female connector. C US. 79mm.0 76mm Other Accessories Recessed Male Receptacle with 6 (.8m) cord (no female connectors) Model Number Volts Amps RM5-5 RM6-5 RM5-2Ø RM6-2Ø Model Number Volts Amps Female Connector - for extension cords FMG2ØA FM2G2ØA 20 5/20 5/20 Hinged Cover Model Number Description.25 82mm. 79mm *FC-KH lack/hotstart Logo FC-KH-C Chrome/HOTSTART Logo.0 76mm *Standard with kit Model Number Plug Housing A-222-PH Customer Service: hotstart.com 5

54 Specifying an Engine Heater. Determine the best type of heater to be used for the application. In-block or Thermosiphon 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.. Determine wattage required by using this general formula: watts x cubic inch displacement = watts required. Example: Engine is 855 CID. Requirement is 2500 watt heater. (855 x = 2565) This formula is a very good rule of thumb to use down to 0 F (-8 C) ambient temperature. This formula will generally hold engine temperature at approximately 00 F (8 C) above ambient. Engines over 250 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 (20,, 277,, 80, ). Is the power source Single Phase or Three Phase? 5. For thermostat selection, determine the desired engine temperature to be maintained. 00 F (8 C) to 20 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 5. If you have other questions or need additional assistance, please contact our customer service department. Conversion Factors Litres x.0567 = Quarts Quarts x = Litres Litres x = Gallons Gallons x.7854 = Litres Cubic Inches - Litres Conversion Chart Cubic Inches Litres Cubic Inches Litres Cubic Inches Litres Cubic Inches x = Liters Liters x = Cubic Inches Temperature Fahrenheit Celsius -40 F -40 C -0 F -4 C -20 F -29 C -0 F -2 C 0 F -8 C 0 F -2 C 20 F - 7 C 0 F - C 40 F 4.5 C 50 F 0.0 C F 5.5 C 70 F 2.0 C 80 F 27.0 C 90 F 2.0 C 00 F 8.0 C 0 F 4.0 C 20 F 49.0 C 0 F 54.0 C 40 F.0 C 50 F 65.5 C F 7.0 C 70 F 77.0 C 80 F 82.0 C 90 F 88.0 C 200 F 9.0 C 20 F 99.0 C C x = F (F - 2) x 0.55 = C 54 Customer Service: hotstart.com

55 HOTSTART forced circulation preheating systems are ideal for engines ranging in size from 0 L to the largest displacement currently in production. These systems are designed specifically for installation on a generator, compressor package, marine engine or locomotive. HOTSTART offers forced circulation heating systems for coolant heating, 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. Forced Circulation Heating Systems For additional information regarding HOTSTART s forced circulation heating systems, please visit or contact HOTSTART and have all your questions answered by one of our engine heating product specialists. CMM/CLM Models Coolant-only Heating Systems Voltage Range: V Heat Power: 6 44 kw CLA/CLE Models 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 Oil-only Heating Systems Voltage Range: V Heat Power: 2 kw OLA/OLE Models 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 OCLA/OCLE Models Auxiliary Power Unit for Locomotive Engines Voltage Range: 20 V, 400 V Heat Power (Oil): kw Heat Power (Coolant): 6 6 kw The HOTSTART APU allows an idling locomotive to be shut down in cold weather at any location. This self-contained system runs off the locomotive s fuel supply. It will maintain water temperature at 00 F (8 C) above ambient and provides cab heat. Customer Service: hotstart.com 55

56 Corporate and Manufacturing Headquarters 572 E Alki Ave Spokane, WA 9922 USA sales@hotstart.com Oil & Gas Office 272 Provincial lvd Suite 70 Katy, TX USA oil.gas@hotstart.com Europe Office HOTSTART GmbH Am Turm Siegburg Germany europe@hotstart.com Asia Pacific Office HOTSTART Asia Pacific Ltd F, Honkomagome unkyo-ku, Tokyo -002, Japan apac@hotstart.com Customer Services Warranty Information To better serve you, HOTSTART provides a customer service department to answer all your engine heating concerns and questions or to take your sales order. Customer Service Department: Sales orders and requests for quotes can also be faxed to our toll-free FAX line. Toll-free FAX line: The warranty below has been drafted to comply with the Federal Law applicable to products manufactured after December, 976. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state. HOTSTART products are warranted against defects in workmanship and materials. No other express warranty, written or oral, applies. No person is authorized to give any other warranty or assume any liability except by written statement from an officer of HOTSTART, Inc. The warranty extends for twelve months from date of shipment from factory or authorized distributor. Products must be installed and maintained in accordance with HOTSTART, Inc. instructions. Users are responsible for the suitability of the products to their application. There is no warranty against damage resulting from corrosion, misapplication, improper specification or other operating conditions beyond our control. Claims against carriers for damage in transit 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, 572 E Alki Ave, Spokane, WA 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 ureau of Industry and Security (IS) website: HOTSTART, Inc. Distributor