Instruction/ maintenance manual of the product R5 Denso
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1 / 29 DENSO R5 Starter Installation Guide LA990009-1943 DENSO R5 Starter Installation Guide For: • 2002 Freightliner C olumbia • Detroit Diesel Series 60 Engine.
2 / 29 DENSO R5 Starter Installation Guide This guide will assist the technician with the installation of the R5 starter on this particular application. These installation procedures may vary based on the engine and make, model & year of the vehicle.
3 / 29 DENSO R5 Starter Installation Guide Read all installation instructions & service information carefully before installing the R5 starter. These items are included with the starter.
4 / 29 DENSO R5 Starter Installation Guide Confirm the correct part number for the particular application. Starter Preparation Visually inspect starter at these critical points.
5 / 29 DENSO R5 Starter Installation Guide Locate the vehicle battery compartment and remove the battery cover. Vehicle Preparation Disconnect and isolate the negative (-) battery cable from the negative (-) battery terminal.
6 / 29 DENSO R5 Starter Installation Guide Remove the wheel well protector on the driver side of the vehicle. Retain all mounting hardware. Vehicle Preparation Proceed to starter removal.
7 / 29 DENSO R5 Starter Installation Guide Before disconnecting cables from the original starter, identify and note location for reassembly. • Disconnect & remove all cables from the starter • Temporarily group all positive (+) cables together.
8 / 29 DENSO R5 Starter Installation Guide Inspect the ring gear for burred or damaged teeth. Rotate the flywheel and observe the condition of the entire ring gear.
9 / 29 DENSO R5 Starter Installation Guide Check the condition of all battery cables. If out of specification, clean cable connectors or replace cables.
10 / 29 DENSO R5 Starter Installation Guide Viewed from bottom of vehicle looking up Temporarily support the R5 starter and secure with the original 3 mounting bolts.
11 / 29 DENSO R5 Starter Installation Guide Viewed from side of vehicle Torque the mounting bolts to the specifications indicated in the Series 60 service manual. Viewed from side of vehicle Starter Installation NOTE: Starter shown from side view with drain tube in the downward position.
12 / 29 DENSO R5 Starter Installation Guide Check for minimum clearances of starter to: 1. Engine Block - 4mm ( .16 inches) 2. Frame Rail - 25mm (1 inch) 3. Heat Source - 30mm (1.2 inches) (e.g. exhaust manifold) Starter Installation Proceed to wiring assembly.
13 / 29 DENSO R5 Starter Installation Guide Starting Motor O vercrank Protection (OCP) Circuit Bypass (if equipped) The OCP circuit is an option used on many trucks. It utilizes a thermal switch to open the starter relay ground circuit when excessive starter temperatures are reached due to prolonged cranking of the starter motor.
14 / 29 DENSO R5 Starter Installation Guide Wiring Assembly Location of over-crank protection terminal in original starter. Jumper plug installed in original wire harness.
15 / 29 DENSO R5 Starter Installation Guide Wiring Assembly Tie off the OCP terminal and jumper plug to the main wire harness to prevent separation due to vibration.
16 / 29 DENSO R5 Starter Installation Guide Loosen the cable bracket holding the alternator cable to the engine block. Remove the ties (adjacent to the engine) holding the positive (+) alternator cable in place.
17 / 29 DENSO R5 Starter Installation Guide Re-align the cable bracket to the original position and torque to specifications. Carefully maneuver the alternator cable through the cable bracket, toward the starter, to allow sufficient length for proper connection to the B+ (30) terminal.
18 / 29 DENSO R5 Starter Installation Guide Loosen the B+ battery cable bracket located under the cab. Cab Mount Starter Mounting Bolt B+ Battery Cable Bracket Wiring Assembly Carefully maneuver the positive (+) battery cable, toward the starter, to allow sufficient length for proper connection to the B+ (30) terminal.
19 / 29 DENSO R5 Starter Installation Guide Wiring Assembly Remove the temporary tie securing the positive (+) cables and wiring. Re-secure the B+ battery cable bracket located under the cab.
20 / 29 DENSO R5 Starter Installation Guide Connect the key switch wire to the 50 terminal and secure with retaining nut. Tighten and torque to: 2.6-4.6 Nm, 27-48 k gf.cm, 1.5-2.2 lbt. ft. Do not over-tighten terminal retaining nut. Extend the key switch wire and relay circuit within the wiring harness protector approximately 1 inch.
21 / 29 DENSO R5 Starter Installation Guide Wiring Assembly Replace positive (+) cables on the B+ (30) terminal and secure in place with retaining nut. Tighten and torque B+ (30) terminal retaining nut to: 23-30 Nm, 239-304 kgf .cm, 17.7-22.0 l bt.ft.
22 / 29 DENSO R5 Starter Installation Guide Rotate cable in counter-clockwise direction to allow sufficient length to connect to the starter ground terminal (Terminal G). Re-torque mounting bolt to engine block according to specifications. Loosen the engine ground cable from the engine block.
23 / 29 DENSO R5 Starter Installation Guide Tighten and torque the Terminal G retaining nut to: 23-30 Nm, 239-304 kgf .cm, 17.7-22.0 l bt.ft. Do not over-tighten terminal retaining nut. Wiring Assembly Connect ground cables to the ground terminal (Terminal G) of the starter.
24 / 29 DENSO R5 Starter Installation Guide Properly route and re-secure all cable wiring with new cable ties to avoid contact with frame rail and any external heat source.
25 / 29 DENSO R5 Starter Installation Guide Re-install the wheel well protector with original hardware. Check the voltage of all batteries. Each battery should be fully charged.
26 / 29 DENSO R5 Starter Installation Guide Cable Voltage Loss Test (Step 1) 1. Connect Voltmeter & Carbon File Loader as shown in Diagram 1. 2. Crank engine & adjust load on Carbon Pile Loader to 500 Amps. 3. Record (+V) value indicated on Voltmeter.
27 / 29 DENSO R5 Starter Installation Guide Inspection After Installation Cable Voltage Loss Test (Step 2) 1. Move Voltmeter to (-) side, as shown. 2. Crank engine & adjust load on Carbon Pile Loader to 500 Amps. 3. Record (-V) value indicated on Voltmeter.
28 / 29 DENSO R5 Starter Installation Guide Replace ALL removed vehicle components. Start engine and check for proper operation. Inspection After Installation.
29 / 29 DENSO R5 Starter Installation Guide CONGRATULATIONS! You have successfully installed the DENSO R5 Starter. For Additional Assistance or Technical Support Contact: DENSO Sales California, Inc.
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