SFN-20240425B -  Install a Denso PA90S starter and associated cabling B6.7N CNG

TICO Document #: SFN -20240425B (formerly TES -261)

Complication: Delco-Remy 35MT starters are no longer available.

Description of Procedure: Delco-Remy is no longer manufacturing the 35MT series starter.​ Install a Denso PA90S starter and associated cabling. ​

Units Affected: B6.7N CNG engines that were shipped on or before 07/17/18. This rework is required based on Cummins IQA approval.

Parts Required:

Planned Labor: 1 hour

Instructions:

1. Park vehicle on flat surface, apply parking brake, and chock wheels. If your company utilizes a “Lock Out, Tag Out” policy, you should employ it during this procedure.

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2. Ensure that the vehicle is parked on a flat surface, apply parking brake, and chock wheels.

   Figure 1 shows a CUMMINS QSB-IVF powered off-road tractor.

3. Grasp the cab lift handle located on the right-hand side of the tractor. Pull it towards the rear of the tractor. Refer to Figure 2a.

4. Raise the cab using the cab lift switch. Refer to Figure 2b.

5. Ensure that the cab is raised to its highest position to allow for access to the engine. Refer to Figure 2c.

6. Undo the (2) latches on the battery box cover. Refer to Figure 3a.

7. Remove the cover. Refer to Figure 3b.

8. Remove battery box cover and disconnect ground battery cables (black cables) using a 3/4” socket. Retain all hardware.

9. Using an 18 mm socket, remove (2) hex nuts and (2) washers from the studs on the Delco-Remy 35 MT starter. Discard the hardware.

   Refer to Figure 5.

10. Using 7/16” and 1/2” sockets, remove (2) hex nuts and (2) washers from the studs on the alternator. Retain this hardware. Refer to Figures 6a and 6b.

    

11. Using a 3/4” socket, remove (1) hex nut and (1) washer from the positive stud of the battery. Retain this hardware.

    Refer to Figure 7.

12. Cut any zip ties that are securing the (2) cables from the starter to the battery. Refer to Figure 8a.

13. Cut any zip ties that are securing the (2) cables from the starter to the alternator. Refer to Figure 8b.

14. Remove the (2) cables from the starter to the alternator and the (2) cables from the starter to the battery. Refer to Figure 9.

15. These (4) cables can be discarded as replacement cables are included in this upfit kit.

16. Using a 16 mm socket, remove and retain (3) M10 mounting bolts from the Delco-Remy 35MT starter. Refer to Figure 10a.

17. Remove the starter from the engine and discard it. Refer to Figure 10b.

18. With a 16 mm socket, mount the Denso PA90S starter P/N: 91964 onto the engine using (2) of the retained M10 bolts. Refer to Figure 11.

Note: The bolts should be torqued to 384 in. – lbs

19. For the negative stud on the starter:

    Install (1) cable P/N: 91223 (3/0 GA, black, 56” long cable) 

    Install (1) cable P/N: 91133 (2 GA, black, 46” long cable)

    For the positive stud on the starter:

    Install (1) cable P/N: 61522 (3/0 GA, red, 57.5” long cable)

    Install (1) cable P/N: 90798 (2 GA, red, 43” long cable)

    Refer to Figure 12.

20. Using an 18 mm socket, install (2) hex nuts and (2) washers onto the studs of the starter.

    Note: The hex nuts should be torqued to 159 - 221 in. – lbs.

    Refer to Figure 13.

21. Install the other end of cable P/N: 91133 onto the negative stud of the alternator.

22. Install the other end of cable P/N: 90798 onto the positive stud of the alternator.

    Refer to Figure 14.

23. Reinstall the (2) hex nuts and (2) washers that were previously retained onto the studs on the alternator.

    Refer to Figures 15a and 15b.

24. Using (8) double-loop cable ties P/N: 420446 and (6) single-loop cable ties P/N: 420444, secure the (4) new battery cables. Refer to Figures 16a and 16b.

    Note: The double-loop cable ties P/N: 420446 should be used to separate the power and ground cables to prevent chaffing.

25. Using (2) double-loop cable ties P/N: 420446, secure the (2) new battery cables near the alternator. Refer to Figure 17. 

26. Install the other end of P/N: 91223 (3/0 GA, black, 56” long cable) onto the negative stud of the battery.

27. Install the other end of P/N: 61522 (3/0 GA, red, 57.5” long cable) onto the positive stud of the battery.

28. Reinstall (1) hex nut and (1) washer using a 3/4” socket onto each battery stud. Refer to Figure 18.

    Note: The nuts should be torqued to 80 - 100 in. – lbs.

29. Apply dielectric grease to the battery and starter studs. Refer to Figures 19a and 19b.

30. Apply dielectric grease to the alternator studs. Refer to Figure 20.

31. Reinstall the battery box lid and secure it using the (2) latches on the side.

    Refer to Figure 21.

32. Grasp the cab lift handle located on the right-hand side of the tractor. Pull it towards the rear of the tractor. Refer to Figure 22a.

33. Lower the cab using the cab lift switch. Refer to Figure 22b.

34. Ensure that the cab is completely lowered. Refer to Figure 22c.

35. Start the vehicle to ensure proper function.

36. Remove the wheel chocks.

37. Remove “Lock Out, Tag Out” plaque.

38. Return vehicle to service.