Denso R5 User manual

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DENSO R5 Starter Installation Guide
LA990009-1943
DENSO R5 Starter
Installation Guide For:
• 2002 Freightliner Columbia
• Detroit Diesel Series 60 Engine

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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.
Prior to component replacement carefully troubleshoot
the starting circuit to identify the true cause of failure.
All replaced cables or wiring should match original
(OEM) specifications AND when reinstalling bolts and
hardware, torque to original specifications.

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DENSO R5 Starter Installation Guide
Read all installation instructions & service information carefully before
installing the R5 starter.
These items are included with the starter.
Starter Preparation
Installation Instructions Service Information Caution Tag

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DENSO R5 Starter Installation Guide
Confirm the correct part number for
the particular application.
Starter Preparation
Visually inspect starter at these
critical points.
Proceed to vehicle preparation.

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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.

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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.

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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.
• Temporarily group all negative (-)
cables together.
Starter Removal
Remove the original starter from
the vehicle.
Save the original mounting
hardware for the DENSO R5
starter installation.
Proceed to inspection.

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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.
Replace any ring gear with damaged
or worn teeth.
Inspection

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DENSO R5 Starter Installation Guide
Check the condition of all battery
cables. If out of specification, clean
cable connectors or replace cables.
Inspection
Proceed to starter installation.

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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.
• Ensure the drain tube is in the
downward position
Starter Installation
Viewed from bottom of vehicle looking up

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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.

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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.

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DENSO R5 Starter Installation Guide
Starting Motor Overcrank 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. This is commonly called over-cranking.
The information below describes the procedure to bypass the OCP circuit when
replacing an OCP equipped starter with a DENSO R5 starter.
The presence of OCP can be identified by looking at the original starter (commutator
end view). 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.
This can be accomplished by installing a jumper plug into the OCP wiring harness
connector.
• DENSO OCP Jumper Plug Part #053680-8010
Wiring Assembly

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DENSO R5 Starter Installation Guide
Wiring Assembly
Location of over-crank protection
terminal in original starter.
Jumper plug installed in original wire
harness.
(if equipped with over-crank protection)

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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.
(if equipped with over-crank protection)

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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.
Wiring Assembly

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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.
Wiring Assembly

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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.

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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.

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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 kgf.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.
Wiring Assembly