IK0800503

IK0800503 ­ ISB Starting System Diagnostics
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Countries:
CANADA, UNITED STATES Document ID: IK0800503
Availability:
ISIS, Bus ISIS, FleetISIS
Revision:
13
Major System:
ELECTRICAL SYSTEM
Created:
10/22/2014
Current Language: English
Last Modified: 10/29/2015
Other Languages: NONE
Author:
Viewed:
David Smith
5803
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Title : ISB Starting System Diagnostics
Applies To : ISB Engine
CHANGE LOG
10/29/2015 - Added Extra decision to step 2 if clunk noise is heard. Added SRT link, and fixed format issues
09/10/2015 - Changed verbiage in step 7 per feedback request. Added Warranty Note under Description
07/09/2015 - Updated link in Step 11
06/25/2015- Inserted break date for plant production update & control circuit update installation instruction
06/04/2015- Updated flexplate part numbers to match Automatic Transmission feature codes
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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.
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
SPECIAL TOOLS / SOFTWARE
Tool Description
Cummins Insite
Tool Number
Comments
Cummins Tool
Midtronics ESP
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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
Perform battery test:
4
Decision
Yes. Replace ONLY failed battery and
then recheck for symptom
Follow IK0800482- Battery Testing, Diagnostics & Maintenance
No. Step 5
Is a warranty approval code (WAC) or failed battery result from any battery
generated?
Step Action
5
Starter Cable Voltage Drop Test:
Decision
Yes. Make required repair
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No. Step 6
Follow Midtronics starter cable voltage drop test
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
Starter Control Circuit Check:
Decision
Yes. Perform starter control diagnostics for
possible causes:
Wiring
Connect DVOM test leads on IMS (Mag switch) "S terminal" and ground to solenoid F3A Fuse
Start Relay (Neutral Relay)
case as indicated in Figure 1
Crank Inhibit Relay
7
Have an assistant hold keyswitch in start position for 5 seconds.
Compare DVOM IMS (Mag switch) "S terminal" reading to B+ voltage at batteries
Clutch Switch (Manual Trans)
TCM (Auto Trans)
ECM
Key Switch
No. Step 8
Does the DVOM not read battery voltage +/-0.5 volts?
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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
Flexplate replacement determination:
9
Decision
Yes. Replace flexplate & starter and then
go to step 10
No. Replace starter and then go to step
10
Does the flexplate need to be replaced when ring gear teeth are compared to
Figure 3?
Step Action
Build date inspection:
Decision
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?
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Figure 4: Rectifier Diode Inspection
Step Action
Decision
Overlay harness inspection:
11
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
­Durastar located near relay block
No. Follow instructions Click Here
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
Starter Motor Replacement CE Bus
Cummins ISB
GY08-4202SB
Starter Motor Replacement 4300
Cummins ISB
KL08-4202SB
CE Bus
Cummins ISB
GY13-9114SB
4300
Cummins ISB
KL13-9114SB
Flexplate Replacement
CE Bus
Cummins ISB
GY13-9114SB-1
Flexplate Replacement
4300
Cummins ISB
KL13-9114SB-1
Automatic Transmission
(Removal & Reinstall)
Automatic Transmission
(Removal & Reinstall)
SRT Times
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OTHER RESOURCES
Master Service Information Site
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Copyright © 2015 Navistar, Inc.
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