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Manual Denso R5

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  • Denso R5 - page 1

    1 / 29 DENSO R5 Starter Installation Guide LA990009-1943 DENSO R5 Starter Installation Guide For: • 2002 Freightliner C olumbia • Detroit Diesel Series 60 Engine ...

  • Denso R5 - page 2

    2 / 29 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 ...

  • Denso R5 - page 3

    3 / 29 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 ...

  • Denso R5 - page 4

    4 / 29 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. ...

  • Denso R5 - page 5

    5 / 29 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. ...

  • Denso R5 - page 6

    6 / 29 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. ...

  • Denso R5 - page 7

    7 / 29 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 start ...

  • Denso R5 - page 8

    8 / 29 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 ...

  • Denso R5 - page 9

    9 / 29 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. ...

  • Denso R5 - page 10

    10 / 29 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 ...

  • Denso R5 - page 11

    11 / 29 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. ...

  • Denso R5 - page 12

    12 / 29 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. ...

  • Denso R5 - page 13

    13 / 29 DENSO R5 Starter Installation Guide Starting Motor O vercrank 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 c ...

  • Denso R5 - page 14

    14 / 29 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) ...

  • Denso R5 - page 15

    15 / 29 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) ...

  • Denso R5 - page 16

    16 / 29 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 ...

  • Denso R5 - page 17

    17 / 29 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 ...

  • Denso R5 - page 18

    18 / 29 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. ...

  • Denso R5 - page 19

    19 / 29 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. ...

  • Denso R5 - page 20

    20 / 29 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 k gf.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 Assembl ...

  • Denso R5 - page 21

    21 / 29 DENSO R5 Starter Installation Guide 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 l bt.ft. Do not over-tighten terminal retaining nut. ...

  • Denso R5 - page 22

    22 / 29 DENSO R5 Starter Installation Guide 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. Loosen the engine ground cable from the engine block. Wiring Assembly ...

  • Denso R5 - page 23

    23 / 29 DENSO R5 Starter Installation Guide Tighten and torque the Terminal G retaining nut to: 23-30 Nm, 239-304 kgf .cm, 17.7-22.0 l bt.ft. Do not over-tighten terminal retaining nut. Wiring Assembly Connect ground cables to the ground terminal (Terminal G) of the starter. ...

  • Denso R5 - page 24

    24 / 29 DENSO R5 Starter Installation Guide Properly route and re-secure all cable wiring with new cable ties to avoid contact with frame rail and any external heat source. Wiring Assembly Proceed to inspection after installation. ...

  • Denso R5 - page 25

    25 / 29 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. Inspection After Installation ...

  • Denso R5 - page 26

    26 / 29 DENSO R5 Starter Installation Guide 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. Inspection After Installation Proceed to Step 2. Diagram 1 ...

  • Denso R5 - page 27

    27 / 29 DENSO R5 Starter Installation Guide 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 should not exceed 0.5V. If total loss exceeds 0.5V, r ...

  • Denso R5 - page 28

    28 / 29 DENSO R5 Starter Installation Guide Replace ALL removed vehicle components. Start engine and check for proper operation. Inspection After Installation ...

  • Denso R5 - page 29

    29 / 29 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 ...

Manufacturer Denso Category Automobile Parts

Documents that we receive from a manufacturer of a Denso R5 can be divided into several groups. They are, among others:
- Denso technical drawings
- R5 manuals
- Denso product data sheets
- information booklets
- or energy labels Denso R5
All of them are important, but the most important information from the point of view of use of the device are in the user manual Denso R5.

A group of documents referred to as user manuals is also divided into more specific types, such as: Installation manuals Denso R5, service manual, brief instructions and user manuals Denso R5. Depending on your needs, you should look for the document you need. In our website you can view the most popular manual of the product Denso R5.

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A complete manual for the device Denso R5, how should it look like?
A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Denso R5 by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Denso R5.

A complete Denso manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

1. Preface and tips on how to use the manual Denso R5 - At the beginning of each manual we should find clues about how to use the guidelines. It should include information about the location of the Contents of the Denso R5, FAQ or common problems, i.e. places that are most often searched by users in each manual
2. Contents - index of all tips concerning the Denso R5, that we can find in the current document
3. Tips how to use the basic functions of the device Denso R5 - which should help us in our first steps of using Denso R5
4. Troubleshooting - systematic sequence of activities that will help us diagnose and subsequently solve the most important problems with Denso R5
5. FAQ - Frequently Asked Questions
6. Contact detailsInformation about where to look for contact to the manufacturer/service of Denso R5 in a specific country, if it was not possible to solve the problem on our own.

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