IK0800503 Service Bulletin/Repair Instructions

IK0800503 ­ ISB Starting System Diagnostics
Page 1 of 6
Countries:
CANADA, UNITED STATES
Availability:
ISIS, Bus ISIS, FleetISIS, NotSIR Revision:
Document ID: IK0800503

23
Major System:
ELECTRICAL SYSTEM
10/22/2014
Created:
Current Language: English
Last Modified: 1/23/2017
Other Languages: NONE
Author:
Viewed:
Andrew Boyd
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Title : ISB Starting System Diagnostics

Applies To : ISB Engine
CHANGE LOG

01/23/2017 - Corrected next steps under Step 7.

05/02/2016 - Author addressed feedback.

04/06/2016 - Adjusted Harness install instruction link to reduce field confusion.

04/01/2016 - Author addressed feedback.

03/30/2016 - Added diode inspection location for DuraStar on step 11. Location may vary depending on if plant or dealer installed.
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DESCRIPTION

This document will guide the user through Cummins ISB starter and ring gear diagnostics. It is important to review all the material to

prevent repeat failures, especially in instances of ring gear damage by the starter.

NOTE: Warranty claims with a failure date of 09/21/2015 and later will not be allowed if the complete repair is not performed. See

steps 10 and 11 of the diagnostics. As some vehicles may require an overlay harness to prevent repeat starter motor failures.

Following the step based procedure below will determine if there is an issue with a starter motor and help prevent warranty denials for No

Trouble Found (NTF).

When testing for a Starter related failure, the technician will complete the proper diagnostic worksheet. Critical diagnostic testing values

are to be printed and submitted with the claim.

NOTE: Before performing any voltage drop test; inspect each cable end nut torque, insulation, routing, clipping, discoloration,

and terminal arching
SYMPTOMS

Diagnostic Trouble Codes

DTC/Light
Description
N/A
Customer Observations or Concerns:

Operator may hear one of the following from the starter:

•

•

•

•

•

•

•

•

•
Click

Clunk

Grind

Squeal

Starter spins, doesn't rotate engine

Slow Engine Crank

Click No-Crank

No-Click No-Crank

Crank No-Start
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IK0800503 ­ ISB Starting System Diagnostics
Page 2 of 6
SPECIAL TOOLS / SOFTWARE

Tool Description
Tool Number
Cummins Insite
Comments

Cummins Tool
Midtronics ESP

Tools Resource Center
PARTS

Description

MOTOR,STARTING 12V , 38MT

DELCO

Flexplate

Flexplate
Part Number Quantity Source From Application

8201039
1
Navistar
Engine- ISB
3968672

29545469
1

1
Cummins

Allison
Trans- 0013ASP Allison 2000

Trans- 0013AVE Allison 3000
DIAGNOSTICS

NOTE: Before performing any voltage drop test; inspect each cable end nut torque, insulation, routing, clipping, discoloration,

and terminal arching
Step Action

Diagnostic Trouble Code Check:
1
Decision

Yes. Go to appropriate diagnostic manual

to diagnose crank no start symptom
Review current health report for Cummins or Body Controller fault codes that may

cause an extended crank condition (Crankshaft Position Sensor, Camshaft Sensor,

Fuel System, Electrical codes)

No. Step 2

Are there pending/active/previously active DTC's causing a crank no start?
Step Action

Manual Engine Barring Test:
Decision

Yes. (with no audible clunk noise) Go To

Step 3
Have an assistant bar the engine over from the alternator pulley

2
TIP: If an audible noise is heard from the starter area when the engine is

rotated by hand, there is most likely flexplate ring gear damage.
Does the engine rotate freely, and no clunk noise was heard?

Step Action

Cranking RPM Test:
3
Yes. (With audible clunk noise) Go to Step

4

No. Diagnose engine lock up condition.
Decision

Yes. Go to appropriate Cummins crank no

start diagnostic. Do NOT replace starter

motor
Monitor Engine RPM using Cummins Insite while cranking the engine

No. Step 4

Does the engine crank?
Step Action

4
Perform battery test:
Decision

Yes. Replace ONLY failed battery and

then recheck for symptom
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IK0800503 ­ ISB Starting System Diagnostics
Page 3 of 6
No. Step 5

Follow IK0800482- Battery Testing, Diagnostics & Maintenance
Is a warranty approval code (WAC) or failed battery result from any battery

generated?

Step Action
5
Decision
Starter Cable Voltage Drop Test:
Yes. Make required repair
Follow Midtronics starter cable voltage drop test
No. Step 6
Is combined + & ­ voltage drop greater than 0.5v?

Step Action
6
Decision
Alternator Cable Voltage Drop Test:
Yes. Make required repair
Follow Midtronics alternator cable voltage drop test
No. Step 7
Is combined + & ­ voltage drop greater than 0.5v?
Figure 1: Starter IMS S terminal DVOM Hookup Location

Step Action

7
Starter Control Circuit Check:
Decision

Yes. Step 8:
Connect DVOM test leads on IMS (Mag switch) "S terminal" and ground to solenoid

case as indicated in Figure 1

Have an assistant hold keyswitch in start position for 5 seconds.

Compare DVOM IMS (Mag switch) "S terminal" reading to B+ voltage at batteries
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IK0800503 ­ ISB Starting System Diagnostics
Page 4 of 6
No. PERFORM STARTER CONTROL DIAGNOSITCS

FOR POSSIBLE CAUSES.
Does the DVOM not read battery voltage +/-0.5 volts?
Wiring

F3A Fuse

Start Relay (Neutral Relay)

Crank Inhibit Relay

Clutch Switch (Manual Trans)

TCM (Auto Trans)

ECM

Key Switch
Figure 3: Flexplate/Flywheel Ring Gear

Step Action

Flexplate/Flywheel Ring Gear Inspection:
Decision

Yes. Step 9
Remove starter

Mark the flexplate ring gear with a paint pen

8
Have an assistant bar the engine over while you inspect each tooth for damage:

burrs, milling, chips, etc. (Figure 3)
No. Inspect each tooth
TIP: This can be done as a one man operation using a borescope or by

looking through the starter mount hole
Did all 127 teeth get inspected?

Step Action

9
Flexplate replacement determination:
Decision

Yes. Replace flexplate & starter and then

go to step 10 (Manual Transmission

equipped vehicles End diagnostics

here)
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IK0800503 ­ ISB Starting System Diagnostics
Page 5 of 6
No. Replace starter and then go to step

10 (Manual Transmission equipped

vehicles End diagnostics here)
Does the flexplate need to be replaced when ring gear teeth are compared to

Figure 3?
Step Action
Decision
Build date inspection:
Yes. Step 11

No. Repair complete
10 Inspect truck or bus build date
Was the truck or bus build on or BEFORE 5/31/2015?
Figure 4: Rectifier Diode Inspection

Step Action
Decision
Overlay harness inspection:
Yes. Repair complete (state in warranty

claim the harness was installed prior to

repair)
Inspect for previously installed rectifier diode assembly

-CE Bus located on trunk of harness under dash next to cowl on driver side

11

-Durastar located near relay block, or located beneath the dash by the steering

column.
No. Follow instructions Click Here (Manual

Transmission equipped vehicles do not

click for instructions end diagnostics)
Is the overlay harness with rectifier diode installed when compared to Figure 4?
WARRANTY INFORMATION

Any of the following symptoms should be documented in notes on the warranty claim

Click

Clunk

Grind

Squeal

Slow engine crank

Click no­crank

No-click no-crank

Crank no­start
Warranty Claim Coding:

Group: 08540- Cranking System

Noun: 202- Motor, Starter
Standard Repair Times:

Description
Chassis
Engine
SRT
Starter Diagnostics
CE Bus
Cummins ISB
GY08-2202A
Starter Diagnostics
4300
Cummins ISB
KL08-2202A
SRT Times
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IK0800503 ­ ISB Starting System Diagnostics
Page 6 of 6
Starter Motor Replacement (SRT Not allowed w/ Transmission

Removal)

Starter Motor Replacement (SRT Not allowed w/ Transmission

Removal)
CE Bus
Cummins ISB
GY08-4202SB
4300
Cummins ISB
KL08-4202SB
Automatic Transmission (Removal & Reinstall)
CE Bus
Cummins ISB
GY13-9114SB
Automatic Transmission (Removal & Reinstall)
4300
Cummins ISB
KL13-9114SB
Flexplate Replacement
CE Bus
Cummins ISB
GY13-9114SB-1
Flexplate Replacement
4300
Cummins ISB
KL13-9114SB-1
OTHER RESOURCES

Master Service Information Site

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Copyright © 2017 Navistar, Inc.
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