Denso R5 Installation Guide for Detroit Diesel
Contents
1. 30 terminal retaining nut to MMe e CY NS C 7 FC GS LL ey x 41 NS x DENSO R5 Starter Installation Guide 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 STARTER m block according to specifications DENSO R5 Starter Installation Guide Connect ground cables to the ground terminal Terminal G of the starter uM J gt B s l LE 4 x d 77 y am 4 gt iC 77 MEA Ss T re LEAT ee Pee MI TI ues M Ir THA ras UUs MILAN WAS A Cx Tighten and torque the Terminal G retaining nut to LUTTE n DENSO R5 Starter Installation Guide Wiring Assembly rj Properly route and re secure all cable wiring with new cable ties to avoid contact with frame rail and any external heat source Proceed to inspection after installation 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 TY IW UNa amp Te Ue DENSO R5 Starter Installation Guide Inspection After Installation ike lal Starter System Cable Voltage Loss Test Step 1 1 Connect Voltmeter amp Carbon File Loader as shown in Diagram 1 tometer Carbon Pile Loader 2 Cr2. cables Proceed to starter installation DENSO R5 Starter Installation Guide Starter Installation Temporarily support the R5 starter and secure with the original 3 mounting bolts e Ensure the drain tube is in the downward position Viewed from bottom of vehicle looking up B 30 TERMINAL Viewed from bottom of vehicle looking up EXTENSION TERMINAL 319IH3A dO LNO N4 4 DENSO R5 Starter Installation Guide l D NOTE C X rH 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 Starter Installation Does Vye Minimum 4mm N 1 ENGINE BLOCK Check for minimum clearances of starter to 1 Engine Block 4mm 16 inches 2 Frame Rail 25mm 1 inch e ES AJ O Z O Tl lt m O jn m Minimum 25mm DRAIN TUBE 3 Heat Source 30mm 1 2 inches e g exhaust manifold P n ee 2 FRAME RAIL Proceed to wiring assembly DENSO R5 Starter Installation Guide Wiring Assembly 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 o
3. ank engine amp adjust load on Carbon Pile Loader to 500 Amps EN o Sven Diagram 1 3 Record V value indicated on Voltmeter p 2 Proceed to Step 2 DENSO R5 Starter Installation Guide Inspection After Installation Starter System 4 Wl Autometer Carbon Pile Loader Cable Voltage Loss Test Step 2 Battery V aaa 1 Move Voltmeter to side as shown Bes a Voltmeter v 2 Crank engine amp adjust load on Carbon Pile Loader to 500 Amps Diagram 2 3 Record V value indicated on Voltmeter E x 22 8 gt 4 Add V and V value Total loss should not exceed 0 5V If total loss exceeds 0 5V repair or replace cable R5 0 In accordance with The Maintenance Bor me Council RP129 Section 1 B so Termina DENSO R5 Starter Installation Guide DENSO Replace removed vehicle components Start engine and check for proper operation 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 Tech Hotline at 1 800 366 1123 DENSO R5 Starter Installation Guide DENSO
4. lding the alternator cable to the engine block NT LM L e LL i TEMPI emm E DENSO R5 Starter Installation Guide Carefully maneuver the alternator cable through the cable bracket toward the starter to allow sufficient length for proper connection to the B 30 terminal Re align the cable bracket to the original position and torque to specifications DENSO R5 Starter Installation Guide mor vu LM SN cab Jus JBracket Cab Mount Starter Mounting Loosen the B battery cable bracket Wie located under the cab Eu Carefully maneuver the positive battery cable toward the starter to allow sufficient length for proper connection to the B 30 terminal CMTE DENSO R5 Starter Installation Guide 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 Wiring Assembly ORIGINAL MODIFIED Extend the key switch wire and relay circuit within the wiring harness protector approximately 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 Ibt ft Do not over tighten terminal retaining nut DENSO R5 Starter Installation Guide Replace positive cables on the B 30 terminal and secure in place with retaining nut Tighten and torque B
5. o service information DSCA publication no LA990009 1893 H before installation A Always wear eye protection before performing any mechanical repairs to a vehicie Definition of Terms A WARNING Describes precautions that should be observed In order to prevent injury or cleath to the usor during installation Deecribes precautions that should be observed to prevent damage to the venicie or RS components which may occur dunng inetailation f sufficient care is not taken Provides additional information that facilitates instatiation work CAUTION NOTE LPTR Pett at Installation Instructions DSCA NO LA990009 1099 H MODEL R5 Sterter DATE E DENSO Xy mvs PAGE tots SERVICE INFORMATION wacent nonce TITLE RS PS Starter Interchangeability PART NUMBERS AFFECTED A28000 4424 428000 A435 428000 4444 CONDITION The starter in this box may vary Ir ap unit x designed to t n furnicmion ur par form in the specified application CAUTION Proper longue 61 the starter mounting bolis is essential Reler to tha appmpr ato enartacturers service maria for the bolt torque specication improper Li mouri or nuts CAN ead tO personal emury ot vencit damage R5 See part numbers affected above 98 do FUP Renn COCHORE re Tem uocem Hh mue m URN YO frm oe V ton M S CLER I Reet an IN Une Shanes md cingua pnm al Ald 3900 Via Oro Avenise Long bead Calilormea 90410 Lame Imt Service Information Caution Tag These i
6. provided by DIESELUSSA GROUPS more info available at www DieselUSA com e 2002 Freightliner Columbia Detroit Diesel Series 60 Engine Si SS MT As NE X N RERSEISNENENIG Wl tH ES c nm di y ey y gp chutst d WIDE MAL 2i DENSO R5 Starter Installation Guide LA990009 1943 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 amp 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 DENSO R5 Starter Installation Guide Starter Preparation Read all installation instructions amp service information carefully before installing the R5 starter ECZ HEAVY DUTY R5 Heavy Duty Starter Installation Instructions Thank you for purchasing a DENSO RS Heavy Duty Starter This is an isolated ground A type starter The drive ond housing is fosd in position There are different part numbers that fit differant applications Before installing this AS Heavy Duty Starter reed these instructions completely There may be different configurations of starter to engine mounting positions These instructions are for general installation guidance Refer t
7. tems are included with the starter DENSO R5 Starter Installation Guide Confirm the correct part number for the particular application Visually inspect starter at these critical points DENSO R5 Starter Installation Guide 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 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 Before disconnecting cables from the original starter identify and note location for reassembly Disconnect amp remove all cables from the starter Temporarily group all positive cables together e Temporarily group all negative cables together Remove the original starter from the vehicle the original mounting hardware for the DENSO R5 starter installation DENSO R5 Starter Installation Guide 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 DAMAGED RING GEAR DENSO R5 Starter Installation Guide Inspection Check the condition of all battery cables If out of specification clean cable connectors or replace
8. ver 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 e DENSO OCP Jumper Plug Part 053680 8010 DENSO R5 Starter Installation Guide DENSO Wiring Assembly if equipped with over crank protection STARTER 4 di i COM END VIEW dt NO Location of over crank protection terminal in original starter A otp TERMINAL ORIGINAL STARTING MOTOR Jumper plug installed in original wire harness In Il OCP CIRCUIT WIRING DENSO R5 Starter Installation Guide Wiring Assembl if equipped with over crank protection MAIN WIRE HARNESS Pe Tie off the OCP terminal and jumper plug to the main wire harness to prevent separation due to vibration DENSO R5 Starter Installation Guide Remove the ties adjacent to the engine holding the positive alternator cable in place Loosen the cable bracket ho
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