R5.0 STARTER APPLICATION GUIDE FOR CLASS-8 TRUCK, ON-ROAD & OFF-ROAD APPLICATIONS
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1 R5.0 STARTER APPLICATION GUIDE FOR CLASS-8 TRUCK, ON-ROAD & OFF-ROAD APPLICATIONS 2014
2 WHY DENSO? OE Heritage DENSO is one of the world s largest automotive component suppliers with over $38 billion in annual sales. We supply every major auto manufacturer in the world, providing them with the quality and innovation they need to remain on the leading edge of automotive technology. In addition to our automotive customers, we also supply components to virtually all heavy-duty manufacturers worldwide. For decades, we have helped all of our customers to become giants in their industries. Unsurpassed Quality At DENSO, we know that one of the major keys to success for our company and our customers is an unwavering commitment to quality. We strive for, and achieve, zero defects for parts manufactured in the millions in DENSO facilities that are QS9000, ISO9000, and ISO14000 certified. This dedication to quality is clearly recognized by the industry as DENSO has received such prestigious awards as the Deming Award for Quality, the J.D. Power and Associates Chairman s Award and numerous supplier awards fo quality from companies like Toyota, Lexus, General Motors and DaimlerChrysler. Bringing It All To The Aftermarket In the 1980s, DENSO became the first to mass-produce the platinum spark plug and offer it in the aftermarket. A decade later we introduced the world s most advanced spark plug, Iridium Power, which revolutionized the concept of the aftermarket performance plug. By the late 1990s, the world watched with great interest as DENSO unveiled a line of OE-standard premium replacement components under the First Time Fit brand. Today, the First Time Fit line of products includes A/C compressors, cabin air filters, condensers, receiver driers, expansion valves, starters, alternators, oxygen sensors, fuel pumps, oil and air filters, ignition wire sets and wiper blades. Better By Design As you can see, we ve spent decades perfecting our craft a claim few automotive component manufacturers can make. Clearly the DENSO commitment to quality, innovation, and advanced technology is the reason our automotive and heavy-duty components truly are Better by Design.
3 Table of Contents R5.0 Starter Features and Benefits...Page 2 R5.0 Starter Application by OE...Page 3 R5.0 Starter Application by Part Number...Page 4 Specifications...Page 5-17 On-Road Applications...Page Page Page Page Page Page Page Page Page Page Page 14 Off-Road Applications...Page Page Page Page Page Page Page 20 R5.0 Starter Truck/Engine Model Application Chart... Page 21 DENSO Website... Page 22 Heavy Duty Brushless Alternators Reference... Page 23 The illustrations contained in this application guide are for reference only. Please refer to installation instructions for proper mounting procedures. WARRANTY 3 Years / 350,000 Miles (On-Road Applications) 1 Year/Unlimited Miles (Off-Road)
4 SPECIFICATIONS 5.0 kw Weight: approximately 23.8 lbs. Pinion: DP6/8 10 tooth, DP8 10 tooth, and M3 10 tooth (Interchangeable with competitors 11and 12 tooth) DP8/10 11 tooth, DP8 11 tooth Rotation: Clockwise Mount: SAE #3 OCP By-Pass Kit Available Part Number FEATURES / BENEFITS Smallest class-8 starter in the market High durability for the most demanding applications High torque for maximum starting power (improved cold start-ability); highest in the industry. Smooth engagement for improved durability of pinion and ring gear Torque limiter feature to prevent ring gear/drive train breakage. Warranty: 3 years / 350,000 miles (On-Road Applications) 1year/unlimited miles (Off-Road Applications) REVOLUTION (rpm) TORQUE (Nm) OUTPUT(kW) VOLTAGE(V) V R5.0 OUTPUT PERFORMANCE Comparison with P5.0 (SAE J544 Extra Heavy Duty/8V-1000A) R5.0 GEAR RATIO 3.89 P5.0 GEAR RATIO 4.15 kw Nm ENGINE RECOMMENDATION CHART TYPE Offset Reduction Gear Type R5.0 ENGINE DISPLACEMENT rpm [L] SIZE COMPARISON 2 Competitor Starter DENSO P5.0 Starter
5 R5.0 Starter Application By OE OE Name Make/Model Year Engine Voltage kw DENSO Part Number Type Case New Holland MX240 Tractor Cummins 8.3L R Freightliner All 1999 CAT C R Freightliner All CAT C R Freightliner All CAT C R Freightliner All Cummins ISM R Freightliner All Cummins M R Freightliner All Detroit Series * R Freightliner All Detroit Series R Freightliner All Cummins ISX R Freightliner All Cummins ISX R Freightliner All Cummins N R Freightliner All MBE R Freightliner All Cummins ISX R Freightliner All Detroit Diesel R International All CAT C R International All 1998 CAT C R International All CAT C R International All CAT C R International All Cummins ISM R International All Detroit Series R International All Detroit Series R International All Cummins M R International All Cummins N R International All Cummins ISX R International All Cummins ISX R International All Cummins ISX R International All MaxxForce R International All MaxxForce R John Deere WTS Combines PowerTech R John Deere T660 & T670 Combines PowerTech R John Deere C670 Combine PowerTech R John Deere PowerTech 9.0L R John Deere 8030 Series Tractors PowerTech 9.0L R John Deere 9230 Tractors PowerTech 9.0L R John Deere Agrigulture Machinery R R John Deere Combine R J.I. Case TV145 Tractor EEA 6.7L, 6cyl R Kenworth All CAT C R Kenworth All CAT C R Kenworth All CAT C R Kenworth All Cummins ISM R Kenworth All Cummins M R Kenworth All Detroit Series R Kenworth All Detroit Series R Kenworth All Cummins N R Kenworth All 2011 Cummins ISX R Kenworth All Cummins ISX R Mack All Mack E-Tech R Mack All Mack E R Peterbilt All 1999 CAT C R Peterbilt All CAT C R Peterbilt All CAT C R Peterbilt All Cummins ISM R Peterbilt All Cummins M R Peterbilt All Cummins N R Peterbilt All 2011 Cummins ISX R Peterbilt All Cummins ISX R Peterbilt All Detroit Series R Peterbilt All Detroit Series R Sterling All CAT C R Sterling All CAT C R Sterling All Cummins ISM R Sterling All Cummins M R Sterling All Detroit Series * R Sterling All Detroit Series R Sterling All Cummins N R Sterling All MBE R Volvo All Cummins ISM R Volvo All Detroit Series R Volvo All Detroit Series R Volvo All Cummins N R Volvo All VE R Western Star All 1997 CAT C R Western Star All 2007 CAT C R Western Star All 2007 Detroit Series R Western Star All 2007 Detroit Series R Western Star All MBE R Western Star All Cummins ISX R Western Star All Detroit Diesel R * Freightliner with DDS 60 when the fuel filter is outside the frame rail (single fuel filter) WARRANTY... 3 Years / 350,000 Miles (On-Road Applications) 3
6 R5.0 Starter Application By Part Number On-Road Applications Freightliner w/cat C Freightliner w/cat C Freightliner w/cat C Freightliner w/cummins ISM Sterling w/cat C Sterling w/cat C Sterling w/cummins ISM International w/cat C International w/cat C International w/cat C International w/cat C International w/cummins ISM Kenworth w/cat C Kenworth w/cat C Kenworth w/cat C Kenworth w/cummins ISM Peterbilt w/cat C Peterbilt w/cat C Peterbilt w/cat C Peterbilt w/cummins ISM Volvo w/cummins ISM Western Star w/cat C Western Star w/cat C Freightliner w/cummins M Freightliner w/detroit Series * International w/cummins M International w/detroit Series Mack w/e-tech Mack w/e Sterling w/cummins M Sterling w/detroit Series Kenworth w/cummins M Kenworth w/detroit Series Peterbilt w/cummins M Volvo w/detroit Series Western Star w/detroit Series Volvo w/detroit Series Western Star w/detroit Series Freightliner w/cummins ISX Freightliner w/cummins N Sterling w/cummins N International w/cummins ISX International w/cummins N Kenworth w/cummins N Peterbilt w/cummins N Volvo w/cummins N On-Road Applications (Cont.) Freightliner w/mbe Sterling w/mbe Western Star w/mbe Freightliner w/cummins ISX International w/cummins ISX Kenworth w/cummins ISX Peterbilt w/cummins ISX Kenworth w/cummins ISX Peterbilt w/cummins ISX Freightliner w/cummins ISX International w/cummins ISX Volvo VE Freightliner w/detroit Series International w/detroit Series Sterling w/detroit Series Kenworth w/detroit Series Peterbilt w/detroit Series Volvo w/detroit Series Western Star w/detroit Series International w/maxxforce International w/maxxforce Off-Road Applications John Deere w/powertech Engines, C670, T660, T670 & WTS Combines & John Deere w/powertech Engines, 8030 Series & 9230 Tractors Freightliner w/detroit Diesel John Deere Ag. Machinery, John Deere Combine, Case New Holland MX240 Tractor w/ Cummins 8.3L engine J.I. Case TV145 Tractor w/ EEA 6.7L, 6cyl * Freightliner with DDS 60 when the fuel filter is outside the frame rail (single fuel filter) WARRANTY 3 Years / 350,000 Miles 1 Year/Unlimited (On-Road Applications) Miles (Off-Road) 4
7 PINION REST POSITION On-Road SPECIFICATIONS inches TERMINAL G Application: Freightliner w/cat C12, C13 & C15 Freightliner w/cummins ISM International w/cat C11, C12, C13 & C15 International w/cummins ISM Kenworth w/cat C11, C13 & C15 Peterbilt w/cat C12, C13 & C15 Peterbilt w/cummins ISM Sterling w/cat C13 & C15 Sterling w/cummins ISM Volvo w/cummins ISM Western Star w/cat C12 & C inches DIAMETRAL PITCH 6/8 NUMBER OF TEETH 10 (5 ) RATED OUTPUT 5.0kW (SAE J544B CLOCKWISE VIEWED FROM PINION END APPROX. 23 lbs (10.7 kg) WARRANTY 3 Years / 350,000 Miles (On-Road Applications) 5
8 PINION REST POSITION On-Road SPECIFICATIONS inches TERMINAL G Application: Freightliner w/cummins M11 Freightliner w/detroit Series 60 International w/cummins M11 International w/detroit Series 60 Kenworth w/cummins M11 Kenworth w/detroit Series 60 Mack w/e-tech DIAMETRAL PITCH 6/8 NUMBER OF TEETH 10 Mack w/e-7 Peterbilt w/cummins M11 Sterling w/cummins M11 Sterling w/detroit Series 60 Volvo w/detroit Series 60 Western Star w/detroit Series inches RATED OUTPUT 5.0kW (SAE J544B CLOCKWISE VIEWED FROM PINION END APPROX. 23 lbs. (10.7 kg) WARRANTY 3 Years / 350,000 Miles (On-Road Applications) 6
9 On-Road SPECIFICATIONS inches TERMINAL G (5 ) PINION REST POSITION Application: Freightliner w/cummins ISX Freightliner w/cummins N14 International w/cummins ISX International w/cummins N14 Kenworth w/cummins N14 Peterbilt w/cummins N14 Sterling w/cummins N14 Volvo w/cummins N inches DIAMETRAL PITCH 6/8 NUMBER OF TEETH 10 RATED OUTPUT 5.0kW (SAE J544B CLOCKWISE VIEWED FROM PINION END APPROX. 23 lbs. (10.7 kg) WARRANTY 3 Years / 350,000 Miles (On-Road Applications) 7
10 (59 ) On-Road SPECIFICATIONS PINION REST POSITION inches TERMINAL G Application: Freightliner w/mercedes 4000 Sterling w/mercedes MODULE 3 NUMBER OF TEETH inches inches RATED OUTPUT 5.0kW (SAE J544B CLOCKWISE VIEWED FROM PINION END APPROX. 23 lbs. (10. 5 kg) WARRANTY 3 Years / 350,000 Miles (On-Road Applications) 8
11 On-Road SPECIFICATIONS inches TERMINAL G PINION REST POSITION ( ) Application: inches Freightliner w/cummins ISX International w/cummins ISX DIAMETRAL PITCH 6/8 NUMBER OF TEETH 10 RATED OUTPUT Kenworth w/cummins ISX Peterbilt w/cummins ISX 5.0kW (SAE J544B CLOCKWISE VIEWED FROM PINION END APPROX. 24 lbs. (11 kg) WARRANTY 3 Years / 350,000 Miles (On-Road Applications) 9
12 On-Road SPECIFICATIONS inches TERMINAL G (53 ) PINION REST POSITION Application: Volvo VE inches DIAMETRAL PITCH 8 NUMBER OF TEETH 10 RATED OUTPUT 5.0kW (SAE J544B CLOCKWISE VIEWED FROM PINION END APPROX. 24 lbs. (11 kg) WARRANTY 3 Years / 350,000 Miles (On-Road Applications) 10
13 On-Road SPECIFICATIONS Application: Freightliner w/detroit Series 60 International w/detroit Series 60 Kenworth w/detroit Series 60 Peterbilt w/detroit Series DIAMETRAL PITCH 6/8 NUMBER OF TEETH 10 Sterling w/detroit Series 60 Volvo w/detroit Series 60 Western Star w/detroit Series 60 NOMINAL OUTPUT 5.0kW (SAE J544B CLOCKWISE VIEWED FROM PINION END APPROX. 23 lbs. (10.7 kg) WARRANTY 3 Years / 350,000 Miles (On-Road Applications) 11
14 inches TERMINAL G On-Road Specifications inches TERMINAL G PINION REST POSITION (4 ) PINION REST POSITION Application: Freightliner w/cummins ISX International w/cummins ISX Kenworth w/cummins ISX Peterbilt w/cummins ISX i n c h e s DIAMETRAL PITCH 6 NUMBER OF TEETH 10 NOMINAL OUTPUT OPERATION VOLTAGE (AT 20ºC) 5.0kW (SAE J544B CLOCKWISE VIEWED FROM PINION END APPROX. 25 lbs. (11.3 kg) 8V MAX WARRANTY 3 Years / 350,000 Miles (On-Road Applications) 12
15 On-Road Specifications inches TERMINAL G inches TERMINAL G PINION REST POSITION PINION REST POSITION (60 ) Application: International w/maxxforce 11 & DIAMETRAL PITCH 8 NUMBER OF TEETH 10 i n c h e s NOMINAL OUTPUT OPERATION VOLTAGE (AT 20ºC) 5.0kW (SAE J544B CLOCKWISE VIEWED FROM PINION END APPROX. 25 lbs. (11.3 kg) 8V MAX WARRANTY 3 Years / 350,000 Miles (On-Road Applications) 13
16 On-Road Specifications inches TERMINAL G inches TERMINAL G PINION REST POSITION PINION REST POSITION (60 ) Application: Freightliner w/dd DIAMETRAL PITCH 3 NUMBER OF TEETH inches NOMINAL OUTPUT OPERATION VOLTAGE (AT 20ºC) 5.0kW (SAE J544B CLOCKWISE VIEWED FROM PINION END APPROX. 24 lbs. (11 kg) 8V MAX WARRANTY 3 Years / 350,000 Miles (On-Road Applications) 14
17 Off-Road SPECIFICATIONS inches Application: John Deere w/powertech Engines, C670 T660, T670 & WTS Combines & DIAMETRAL PITCH 8/10 NUMBER OF TEETH inches NOMINAL OUTPUT 5.0kW (SAE J544B CLOCKWISE VIEWED FROM PINION END APPROX. 23 lbs. (10.7 kg) WARRANTY3 1Year/Unlimited Miles (Off-Road Applications) 15
18 Off-Road SPECIFICATIONS inches Application: John Deere w/ 9230 Tractors DIAMETRAL PITCH 8/10 NUMBER OF TEETH inches NOMINAL OUTPUT 5.0kW (SAE J544B CLOCKWISE VIEWED FROM PINION END APPROX. 23 lbs. (10.7 kg) WARRANTY3 1 Year/Unlimited Miles (Off-Road Applications) 16
19 Off-Road SPECIFICATIONS inches Application: John Deere Agricultural. Machinery, DIAMETRAL PITCH 8 NUMBER OF TEETH inches NOMINAL OUTPUT 5.0kW (SAE J544B CLOCKWISE VIEWED FROM PINION END APPROX. 24 lbs. (11 kg) WARRANTY3 1Year/Unlimited Miles (Off-Road Applications) 17
20 Off-Road SPECIFICATIONS inches (76º) (44º) Application: John Deere Combine, DIAMETRAL PITCH 8/10 NUMBER OF TEETH inches NOMINAL OUTPUT 5.0kW (SAE J544B CLOCKWISE VIEWED FROM PINION END APPROX. 24 lbs. (11 kg) WARRANTY3 1 Year/Unlimited Miles (Off-Road Applications) 18
21 Off-Road SPECIFICATIONS inches PINION REST POSITION (44 ) Application: Case New Holland MX240 Tractor w/ Cummins 8.3L engine DIAMETRAL PITCH 8 NUMBER OF TEETH inches NOMINAL OUTPUT OPERATION VOLTAGE (AT 20ºC) 5.0kW (SAE J544B CLOCKWISE VIEWED FROM PINION END APPROX. 24lbs (11kg) 8V MAX WARRANTY3 1Year/Unlimited Miles (Off-Road Applications) 19
22 Off-Road SPECIFICATIONS inches 1.06 inches (42º) Application: J.I. Case TV145 Tractor w/ EEA 6.7L, 6cyl DIAMETRAL PITCH 8 NUMBER OF TEETH inches NOMINAL OUTPUT OPERATION VOLTAGE (AT 20ºC) 5.0kW (SAE J544B CLOCKWISE VIEWED FROM PINION END APPROX. 24lbs (11kg) 8V MAX WARRANTY3 1 Year/Unlimited Miles (Off-Road Applications) 20
23 R5.0 Starter Truck /Engine Model Application Chart R5 Approved Applications Engine/Truck Model Freightliner Sterling International (Thru MY2006) Peterbilt Kenworth Mack Volvo Western Star CAT C CAT C (C) (D) (E) CAT C CAT C (B) Cummins ISM Cummins ISX Cummins ISX w/ IMS Relay (MY2010-) (MY2007-) Cummins M Cummins N DD S (A) (A) (A) (A) (A) (A) (A&B) (B) DTNA DD13 w/ IMS Relay (F) (F) Mack E-Tech, E MaxxForce 11 w/ IMS Relay MaxxForce 13 w/ IMS Relay (G) (G) MBE Volvo VE Under Development Not Applicable (A) when the fuel filter is outside the frame rail (single fuel filter) (B) 2007 Model Year Only (C) 1998 Model Year Only (D) 1999 Model Year Only (E) 1997 Model Year Only (F) 2007 Model Year Forward (G) 2007 Model Year Forward 21
24 DENSO Heavy Duty Website IMAGES, SCHEMATICS & UPDATED APPLICATION INFORMATION ON THE WEB Additional images, schematics and updated application information is available on our website. Log on to and click the Product Search link. You can look up applications by DENSO part number, product category or competitor cross-reference number. 22
25 SPECIFICATIONS Rated Voltage and Rated Output: - 130A Allowable Max RPM: 10,000 rpm Allowable Belt Load: 980N max Polarity: Negative - Case Grounded Rotation: Clockwise (viewed from pulley end) Approximate Weight: 22.9 lbs FEATURES AND BENEFITS Tested to endure heat producing engines of today and tomorrow Long-life brushless design Heavy-duty front and rear bearings Corrosion resistant rectifi er and rotor Heat resistant windings Non-soldered connections for easier service Compact and lightweight design One wire connection Load dump protection SAE J180 mount / Pad Mount Warranty: 3 years / 350,000 miles (On-Road Applications) 24V J J Output Current (A) AMP PERFORMANCE CURVE TEST CONDITIONS: 13.5V Constant Output 25º C Hot Stabilized DENSO (-130A) 5/16-18 UNC 3mm pin -- 5/16-18 UNC 3mm pin -- Idle RPM Alternator Speed PART NUMBERS & APPLICATIONS Part Number Mount Amperage B-Terminal R-Terminal I-Terminal Application J J Pad Mount 130 Pad Mount 130 5/16-18 UNC 3mm Pin -- 5/16-18 UNC 5/16-18 UNC UNC UNC COMPETITOR Y-Wound Stator Technology Creates High Low RPM UNC UNC 5/16-18 UNC 3mm Pin -- CAT C7, C9, C10, C11, C12, C13, C15, 3176, 3406; Cummins ISB, ISM, ISX, L-10, M11, N14; Detroit Series 60 CAT C7, C9, C10, C11, C12, C13, C , 3176; Cummins ISB, ISM, ISX, L10, M11, M14, N14; Detroit Series 60; Volvo VE D300, VE-250, VE D12B-345 CAT C7, C9, C11, C13, C15; Cummins ISB, ISM, ISX; Detroit Series 60; Mack E7/E-Tech; Mercedes MBE4000 CAT C7, C9, C11, C13, C15; Cummins ISB, ISM, ISX; Detroit Series 60; Mercedes MBE4000 Allis Chalmers, CAT, Clark Equipment, Cummins, Euclid, Fiat-Allis, IHC, Terex, Waukesha, Detroit Diesel, Volvo, White Clark Equipment, Consolidated Diesel, Cummins, Detroit Diesel, IHC, J.I. Case, Navistar 23
26 24 NOTES
27 With the increasing demands placed on trucks and the challenges of keeping fleets moving, the need for stronger and more durable components is constant. That s why Gary Page counts on DENSO Heavy Duty starters and alternators. Because of its long-lasting brushless design, the DENSO alternator leads the industry in customer satisfaction. And DENSO s new R5.0 starter is smaller, lighter and with torque up to 60nM and 5kW output more powerful than competitive units it replaces. Just two more reasons fleet managers everywhere look to DENSO for the solutions to today s challenges. DENSO Heavy Duty starters and alternators. Better quality. Better durability. Better by design. Just ask Gary. For more information or your distributor, visit DENSO Products and Services Americas, Inc.
28 Scan this QR Code with your smart phone. Scannez ce code QR à l aide de votre téléphone intelligent. Escanee este código QR con su teléfono inteligente. HDSA-R5AG-0114 D DENSO 3900 Via Oro Avenue, Long Beach, California For the most recent application information and images of DENSO products, visit Pour les renseignements les plus récents et des images additionnelles des produits DENSO, visitez le site Para obtener la información más reciente de aplicaciones e imágenes de los productos DENSO, visite DENSO Products and Services Americas, Inc. All Rights Reserved. First Time Fit is a registered trademark of DENSO Products and Services Americas, Inc DENSO Products and Services Americas, Inc. Tous droits réservés. First Time FitMD est une marque déposée de DENSO Products and Services Americas, Inc Products and Services Americas, Inc. Todos los derechos reservados. First Time Fit es una marca registrada de DENSO Products and Services Americas, Inc.
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