SFN-20240424B Install a Denso PA90S starter and associated cabling CUMMINS B6.7

TICO Document #: SFN -20240424B (formerly TES -260)

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: CUMMINS B6.7-powered on-road tractors that are equipped with a Delco-Remy 35MT starter.

Parts Required: KIT - STARTER, REPLACEMENT, DELCO-REMY 35MT TO DENSO PA90S, QSB-IVF, B6.7 970089 (QTY 1)

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.

   ---

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

   • Figure 1 shows a CUMMINS B6.7-powered on-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. Remove batteries or insulate terminal ends with a non-conductive wrap to prevent inadvertent contact between battery terminals and cables. See Figure 4.

10. 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.

11. If the tractor is equipped with a Delco-Remy 24SI alternator, continue with the procedure. Refer to Figure 6a.

12. If the tractor is equipped with a Mitsubishi alternator proceed to page 9. Refer to Figure 6b.

13. 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 7a and 7b.

14. Using 10 mm and 13 mm sockets, remove (2) hex nuts and (2) washers from the studs on the alternator. Retain this hardware. Refer to Figures 8a and 8b.

15. 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 9.

16. Cut any zip ties that are securing the (2) cables from the starter to the battery. Refer to Figure 10a.

17. Cut any zip ties that are securing the (2) cables from the starter to the alternator. Refer to Figure 10b.

18. Remove the (2) cables from the starter to the alternator and the (2) cables from the starter to the battery. Refer to Figure 11.

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

20. Using a 16 mm socket, remove and retain (3) M10 mounting bolts from the DelcoRemy 35MT starter. Refer to Figure 12a.

21. Remove the starter from the engine and discard it. Refer to Figure 12b.

22. 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 13.

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

23. 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 14.

24. 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 15.

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

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

    • Refer to Figures 16a and 16b.

27. If the tractor is equipped with a Delco-Remy 24SI alternator, continue with the procedure. Refer to Figure 17a.

28. If the tractor is equipped with a Mitsubishi alternator proceed to page 20. Refer to Figure 17b.

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

    • Refer to Figures 18a and 18b.

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

    • Refer to Figures 19a and 19b.

31. 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 20a and 20b.

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

32. Using (2) double-loop cable ties P/N: 420446, secure the (2) new battery cables near the alternator. Refer to Figures 21a and 21b.

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

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

35. Reinstall (1) hex nut and (1) washer using a 3/4” socket onto each battery stud. Refer to Figure 22.

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

36. Apply dielectric grease to the battery and starter studs. Refer to Figures 23a and 23b.

37. Apply dielectric grease to the alternator studs. Refer to Figures 24a and 24b.

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

    • Refer to Figure 25.

39. 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 26a.

40. Lower the cab using the cab lift switch. Refer to Figure 26b.

41. Ensure that the cab is completely lowered. Refer to Figure 26c.

42. Start the vehicle to ensure proper function.

43. Remove the wheel chocks.

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

45. Return vehicle to service.