NHTSA ID Number: 10154121
Manufacturer Communication Number: IK0800503
TSB/Document Date: 2019-03-04
Summary
ISB
Starting System Diagnostics; Only models built with cummins ISB engines
IK0800503 - ISB Starting System Diagnostics
Page 1 of 8
Countries:
CANADA, UNITED STATES
Availability:
ISIS, Bus ISIS, FleetISIS, NotSIR Revision:
Document ID: IK0800503
Major System:
ELECTRICAL SYSTEM
Created:
28
10/22/2014
Current Language: English
Last Modified: 1/3/2019
Other Languages: NONE
Author:
Viewed:
Charles Schroeder
22773
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Title : ISB Starting System Diagnostics
Applies To : ISB Engine
Change Log
Please refer to the change log text box below for recent changes to this article:
01/03/2019 ‐ Added note under diagnostics "Failure to follow all steps may result in a repeat failure."
11/29/2018 ‐ Updated MidTronics Instruction Manual Hyperlinks.
08/23/2018 ‐ Updated voltage check on Step 7 for clarification based on dealer feedback. Removed date from Step 10 and added feature code for
improved vehicle identification.
09/22/2017 ‐ Author updated for feedback purposes.
01/23/2017 ‐ Corrected next steps under Step 7.
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. Steps 10 and 11
only apply to vehicles with feature code '0508051 ‐ Electrical system MUX fror BC prog only', which are 250k Baud rate vehicles.
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
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IK0800503 - ISB Starting System Diagnostics
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• Click No‐Crank
• No‐Click No‐Crank
• Crank No‐Start
Special Tools / Software
Tool Description
Tool Number
Instructions
Cummins Engine
Diagnostic Software
Cummins Insite
MidTronics inTellect EXP battery and
electrical diagnostic tester
Comments
EXP‐1000‐HD‐NAV
Instruction Manual
Service Tool Resource Center
Service Parts Information
Kit Description
Part Number
Package
Quantity
Source From
Notes
MOTOR,STARTING 12V, 38MT DELCO
8201039
1
Engine‐ ISB
Flexplate
3968672
1
Trans‐ 0013ASP Allison 2000
Flexplate
29545469
1
Trans‐ 0013AVE Allison 3000
Diagnostics
Before performing any voltage drop test; inspect each cable end nut torque, insulation, routing, clipping, discoloration, and terminal
arching.
Failure to follow all steps may result in a repeat failure.
Step Action
Decision
Diagnostic Trouble Code Check:
1
Review current health report for fault codes that may cause an extended crank
condition (Crankshaft Position Sensor, Camshaft Sensor, Fuel System, Electrical
codes)
Are there pending/active/previously active DTC's causing a crank no start?
Step Action
Yes: Go to appropriate diagnostic
manual to diagnose crank no start
symptom
No: Step 2
Decision
Manual Engine Barring Test:
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?
Step Action
Cranking RPM Test:
3
Yes: Step 3
Monitor Engine RPM while cranking the engine.
Does the engine crank?
No: Diagnose engine lock up condition.
Decision
Yes: Go to appropriate crank no start
diagnostic. Do NOT replace starter
motor
No: Step 4
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IK0800503 - ISB Starting System Diagnostics
Step Action
Page 3 of 8
Decision
Perform battery test:
Follow IK0800482‐ Battery Testing, Diagnostics & Maintenance
Yes: Replace ONLY failed battery and
then recheck for symptom
Is a warranty approval code (WAC) or failed battery result from any battery
generated?
No: Step 5
4
Figure 1: Starter cable voltage drop test setup
Step Action
5
Starter Cable Voltage Drop Test:
Follow Midtronics starter cable voltage drop test
Decision
Yes: Make required repair to the cable
with the excessive voltage drop
No: Step 6
The test sends a signal through the circuit at the component under test. The
tester then simultaneously calculates voltage drop on the positive (+) and
negative (–) sides of any circuit as well as the total voltage drop.
Is total circuit voltage drop greater than 1.0v?
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IK0800503 - ISB Starting System Diagnostics
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This procedure is outlined in Chapter 6 of the Midtronics Instruction Manual
Refer to Image 2 above for connecting the tester
Figure 2: Alternator cable voltage drop test setup
Step Action
Decision
Alternator Cable Voltage Drop Test:
Follow Midtronics alternator cable voltage drop test
The test sends a signal through the circuit at the component under test. The
tester then simultaneously calculates voltage drop on the positive (+) and
negative (–) sides of any circuit as well as the total voltage drop.
Yes: Make required repair to the cable
with the excessive voltage drop
6
Is total circuit voltage drop greater than 1.0v?
No: Step 7
This procedure is outlined in Chapter 6 of the Midtronics Instruction Manual
Refer to Image 3 above for connecting the tester
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IK0800503 - ISB Starting System Diagnostics
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Figure 4: Starter IMS S terminal DVOM Hookup Location
Step Action
Decision
Yes: Perform starter control diagnostics
for possible causes:
Starter Control Circuit Check:
Connect DVOM test leads on IMS (Mag switch) "S terminal" and ground to
solenoid case as indicated in Figure 1.
7
Have an assistant hold keyswitch in start position for 5 seconds.
Is measured voltage less than 9v?
•
•
•
•
•
•
•
•
Wiring
F3A Fuse
Start Relay (Neutral Relay)
Crank Inhibit Relay
Clutch Switch (Manual Trans)
TCM (Auto Trans)
ECM
Key Switch
No: Step 8
Figure 2: Flexplate / Flywheel Ring Gear
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IK0800503 - ISB Starting System Diagnostics
Step Action
Page 6 of 8
Decision
Ring Gear Inspection:
Remove starter.
Yes: Step 9
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 2)
TIP: This can be done as a one man operation using a borescope or by looking
through the starter mount hole
No: Inspect each tooth
Did all 127 teeth get inspected?
Step Action
Flexplate replacement determination:
9
Does the flexplate need to be replaced when ring gear teeth are compared to
Figure 3?
Step Action
10 Feature code inspection:
Inspect truck or bus feature code for 250k baud rate identification.
Decision
Yes: Replace flexplate & starter and
then go to step 10
(Manual Transmission equipped
vehicles End diagnostics here)
No: Replace starter and then go to step
10
(Manual Transmission equipped
vehicles End diagnostics here)
Decision
Yes: Step 11
No: Repair complete
Does the truck or bus have feature code 0508051?
• 0508051 indicated the vehicle is 250k baud rate
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IK0800503 - ISB Starting System Diagnostics
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• The feature codes are listed in the components tab of the vehicle
information page in Service Portal
• This inspection will not apply to 500k baud rate vehicles
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
11
• CE Bus located on trunk of harness under dash next to cowl on driver side
• DuraStar located near relay block, or located beneath the dash by the
steering column.
Is the overlay harness with rectifier diode installed when compared to Figure 4?
No: Click Here and follow instructions to
add Rectifier Diode
(Manual Transmission equipped
vehicles do not click for instructions
end diagnostics)
Warranty Information
Any of the following symptoms should be documented in notes on the warranty claim
•
•
•
•
•
•
•
•
Click
Clunk
Grind
Squeal
Slow engine crank
Click no‐crank
No‐click no‐crank
Crank no‐start
Warranty Claim Coding:
Group: 08540‐ Cranking System
Noun: 202‐ Motor, Starter
Standard Repair Times:
Description
Chassis
Engine
SRT
Starter Diagnostics
CE Bus
GY08‐2202A
Starter Diagnostics
4300
KL08‐2202A
Starter Motor Replacement (SRT Not allowed w/ Transmission
Removal)
CE Bus
GY08‐4202SB
Starter Motor Replacement (SRT Not allowed w/ Transmission
Removal)
4300
KL08‐4202SB
Automatic Transmission (Removal & Reinstall)
CE Bus
GY13‐9114SB
Automatic Transmission (Removal & Reinstall)
4300
KL13‐9114SB
Flexplate Replacement
CE Bus
GY13‐9114SB‐1
SRT Times
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IK0800503 - ISB Starting System Diagnostics
Page 8 of 8
Flexplate Replacement
4300
KL13‐9114SB‐1
Other Resources
Master Service Information Site
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Copyright © 2019 Navistar, Inc.
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TSB/Document ID: IK0800503
Replacement Service Bulletin Number:
MFR Communication Date: 2019-01-03
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ELECTRICAL SYSTEM:STARTER ASSEMBLY
MFR Component System:
MFR Component Subsystem:
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