Summary of Contents for Denso R5
- Page 1 DENSO R5 Starter Installation Guide For: • 2002 Freightliner • Detroit Diesel Series 60 Engine DENSO R5 Starter Installation Guide LA990009-1943 olumbia 1 / 29...
- Page 2 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. Prior to component replacement carefully troubleshoot the starting circuit to identify the true cause of failure.
- Page 3 Starter Preparation Read all installation instructions & service information carefully before installing the R5 starter. Installation Instructions Service Information Caution Tag These items are included with the starter. DENSO R5 Starter Installation Guide 3 / 29...
- Page 4 Starter Preparation Confirm the correct part number for the particular application. Visually inspect starter at these critical points. Proceed to vehicle preparation. DENSO R5 Starter Installation Guide 4 / 29...
- Page 5 Vehicle Preparation Locate the vehicle battery compartment and remove the battery cover. Disconnect and isolate the negative (-) battery cable from the negative (-) battery terminal. DENSO R5 Starter Installation Guide 5 / 29...
- Page 6 Vehicle Preparation Remove the wheel well protector on the driver side of the vehicle. Retain all mounting hardware. Proceed to starter removal. DENSO R5 Starter Installation Guide 6 / 29...
- Page 7 • Temporarily group all positive (+) cables together. • Temporarily group all negative (-) cables together. Remove the original starter from the vehicle. Save the original mounting hardware for the DENSO R5 starter installation. Proceed to inspection. DENSO R5 Starter Installation Guide 7 / 29...
- Page 8 Inspection Inspect the ring gear for burred or damaged teeth. Rotate the flywheel and observe the condition of the entire ring gear. Replace any ring gear with damaged or worn teeth. DENSO R5 Starter Installation Guide 8 / 29...
- Page 9 Inspection Check the condition of all battery cables. If out of specification, clean cable connectors or replace cables. Proceed to starter installation. DENSO R5 Starter Installation Guide 9 / 29...
- Page 10 Starter Installation Temporarily support the R5 starter and secure with the original 3 mounting bolts. • Ensure the drain tube is in the downward position Viewed from bottom of vehicle looking up Viewed from bottom of vehicle looking up DENSO R5 Starter Installation Guide...
- Page 11 Starter shown from side view with drain tube in the downward position. Torque the mounting bolts to the specifications indicated in the Series 60 service manual. DENSO R5 Starter Installation Guide Viewed from side of vehicle Viewed from side of vehicle 11 / 29...
- Page 12 Check for minimum clearances of starter to: 1. Engine Block - 2. Frame Rail - 25mm 3. Heat Source - 30mm (e.g. exhaust manifold) Proceed to wiring assembly. DENSO R5 Starter Installation Guide (.16 inches) (1 inch) (1.2 inches) 12 / 29...
- Page 13 The OCP terminal comes out of the main wire harness and is plugged into the thermal switch at the rear of the starter. The DENSO R5 kW starter does not require or have an external OCP device. However, it is necessary to complete the relay ground circuit when installing an R5 kW in a vehicle originally equipped with this OCP device.
- Page 14 Wiring Assembly (if equipped with over-crank protection) Location of over-crank protection terminal in original starter. Jumper plug installed in original wire harness. DENSO R5 Starter Installation Guide 14 / 29...
- Page 15 Wiring Assembly (if equipped with over-crank protection) Tie off the OCP terminal and jumper plug to the main wire harness to prevent separation due to vibration. DENSO R5 Starter Installation Guide 15 / 29...
- Page 16 Wiring Assembly Remove the ties (adjacent to the engine) holding the positive (+) alternator cable in place. Loosen the cable bracket holding the alternator cable to the engine block. DENSO R5 Starter Installation Guide 16 / 29...
- Page 17 B+ (30) terminal. Re-align the cable bracket to the original position and torque to specifications. DENSO R5 Starter Installation Guide 17 / 29...
- Page 18 Loosen the B+ battery cable bracket Bolt located under the cab. Carefully maneuver the positive (+) battery cable, toward the starter, to allow sufficient length for proper connection to the B+ (30) terminal. DENSO R5 Starter Installation Guide 18 / 29...
- Page 19 Wiring Assembly Re-secure the B+ battery cable bracket located under the cab. Remove the temporary tie securing the positive (+) cables and wiring. DENSO R5 Starter Installation Guide 19 / 29...
- Page 20 1 inch. 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 kgf.cm, 1.5-2.2 lbt.ft. Do not over-tighten terminal retaining nut. DENSO R5 Starter Installation Guide 20 / 29...
- Page 21 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 lbt.ft. Do not over-tighten terminal retaining nut. DENSO R5 Starter Installation Guide 21 / 29...
- Page 22 Loosen the engine ground cable from the engine block. 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. DENSO R5 Starter Installation Guide 22 / 29...
- Page 23 Connect ground cables to the ground terminal (Terminal G) of the starter. Tighten and torque the Terminal G retaining nut to: 23-30 Nm, 239-304 kgf.cm, 17.7-22.0 lbt.ft. Do not over-tighten terminal retaining nut. DENSO R5 Starter Installation Guide 23 / 29...
- Page 24 Wiring Assembly Properly route and re-secure all cable wiring with new cable ties avoid contact with frame rail and any external heat source. Proceed to inspection after installation. DENSO R5 Starter Installation Guide 24 / 29...
- Page 25 Inspection After Installation Re-install the wheel well protector with original hardware. Check the voltage of all batteries. Each battery should be fully charged. DENSO R5 Starter Installation Guide 25 / 29...
- Page 26 Connect Voltmeter & Carbon File Loader as shown in Diagram 1. Crank engine & adjust load on Carbon Pile Loader to 500 Amps. Record (+V) value indicated on Voltmeter. Proceed to Step 2. DENSO R5 Starter Installation Guide 26 / 29 Diagram 1...
- Page 27 Voltmeter. Add +V and -V value. Total loss should not exceed 0.5V. If total loss exceeds 0.5V, repair or replace cable. In accordance with The Maintenance Council RP129 Section 1(B). DENSO R5 Starter Installation Guide 27 / 29 Diagram 2...
- Page 28 Inspection After Installation Replace removed vehicle components. Start engine and check for proper operation. DENSO R5 Starter Installation Guide 28 / 29...
- Page 29 CONGRATULATIONS! You have successfully installed the DENSO R5 Starter. For Additional Assistance or Technical Support Contact: DENSO Sales California, Inc. Tech Hotline at 1.800.366.1123 DENSO R5 Starter Installation Guide 29 / 29...