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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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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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Page 4
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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Page 7
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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Page 12
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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Page 17
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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Page 18
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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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.
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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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Page 22
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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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.
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Page 26
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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