There is nothing worse than turning the ignition key and having the starter growl with more intensity than a Belgian Malinois, vehemently guarding its owner’s property. The Cummins may start, but the starter’s ability to continue performing its job will be short-lived. When replacing a starter, rather than installing a replacement factory unit, this would be a great time to upgrade to a Powermaster Ultra Duty starter (catalog pages 32-33) designed for the Cummins engine.
With an ultra-high compression ratio Cummins, the workload on the starter is significantly increased. A diesel’s starter amperage draw may be three times greater than a Hemi-equipped Ram. For the high amperage demands of diesel engines, the starting systems are often equipped with two high-amp rated (Cold Cranking Amps (CCA)) batteries connected in parallel (double the amperage output). Before condemning the starter, both batteries must be tested and replaced, if not acceptable. With good batteries, the starter is likely the component that must be replaced if the starting problems continue.
Left: Powermaster’s 9058 starter for 2007-2016 5.9L and 6.7L engines exceeds the factory starter’s performance. It produces 260 ft/lbs. of torque. Center: The Ultra Duty 9053 is designed for all 1994-2003 5.9L Cummins. The starter has the same performance as the 9058, but the gear reduction is numerically lower. Right: The Powermaster 9054 is identical to the 9053, but it is for the 2004-2006 5.9L Cummins engines.
Which Powermaster Ultra Duty starter will fit the Cummins? For the 2007-2016 5.9L and 6.7L engines, the Ultra Duty 9058 starter will exceed the factory starter’s performance. The starter appears stock, but the grouping of permanent magnets and robust armature windings produce 260 ft/lbs. of torque, which surpasses the factory torque by 35 ft/lbs.
The starter provides 2.7 kilowatts of power (3.6 hp), and combined with a 5.5:1 gear reduction, the starter delivers more than enough output to start an 18:1 compression ratio diesel. Although the Ultra Duty starter is muscular, it operates effectively within the factory-spec amperage draw range.
The Powermaster Ultra Duty 9053 is designed for all 1994-2003 5.9L Cummins, and the 9054 handles the 5.9L manufactured from 2004-2006. The 9053 and 9054 starters have the same kilowatt and torque output as the 9058, but the gear reduction is 3.75:1.
Regardless of which starter is required, all three starter designs have an encapsulated solenoid, have a machined aluminum adapter block to ensure the proper fit, and are manufactured in the United States.
When the time comes to replace the factory starter, consider a Powermaster Ultra Duty diesel starter. It will turn over the most aggressive Cummins in any weather or environmental situation while remaining a cost-effective alternative to the stock unit.