Denso R5 User Manual

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DENSO R5 Starter
Installation Guide For:
• 2002 Freightliner Columbia
• Detroit Diesel Series 60 Engine
DENSO R5 Starter Installation Guide
LA990009-1943
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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 hardware, torque to original specifications.
DENSO R5 Starter Installation Guide
when reinstalling bolts and
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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.
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Starter Preparation
Confirm the correct part number for the particular application.
Visually inspect starter at these critical points.
Proceed to vehicle preparation.
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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.
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Vehicle Preparation
Remove the wheel well protector on the driver side of the vehicle. Retain all mounting hardware.
Proceed to starter removal.
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Starter Removal
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.
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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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.
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Inspection
Check the condition of all battery cables. If out of specification, clean
cable connectors or replace cables.
Proceed to starter installation.
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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
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Starter Installation
NOTE: Starter shown from side view with drain tube in the downward position.
Viewed from side of vehicle
Torque the mounting bolts to the specifications indicated in the Series 60 service manual.
Viewed from side of vehicle
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Starter Installation
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)
Proceed to wiring assembly.
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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 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
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Wiring Assembly
(if equipped with over-crank protection)
Location of over-crank protection terminal in original starter.
Jumper plug installed in original wire harness.
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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.
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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.
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Wiring Assembly
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.
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Wiring Assembly
Loosen the B+ battery cable bracket located under the cab.
Starter
Mounting
Bolt
B+ Battery
Cable
Bracket
Cab Mount
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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Wiring Assembly
Re-secure the B+ battery cable bracket located under the cab.
Remove the temporary tie securing the positive (+) cables and wiring.
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Wiring Assembly
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 lbt.ft.
Do not over-tighten terminal retaining nut.
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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 lbt.ft.
Do not over-tighten terminal retaining nut.
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Wiring Assembly
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.
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Wiring Assembly
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.
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Wiring Assembly
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.
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Inspection After Installation
Re-install the wheel well protector with original hardware.
Check the voltage of all batteries. Each battery should be fully charged.
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Inspection After Installation
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.
Diagram 1
Proceed to Step 2.
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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.
4. Add +V and -V value. Total loss
Diagram 2
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).
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Inspection After Installation
Replace ALL removed vehicle components.
Start engine and check for proper operation.
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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
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