Powernet Troubleshooting Guide: Batteries, Path, Alternator,
and Starter
FLA COE
FLB COE
FLD Conventional
Business Class
FLC 112 Conventional

> Century Class Conventional
> Argosy COE
Cargo
> Columbia

54-278
Freightliner
Service Bulletin

> 122SD and Coronado
> Business Class M2
> Cascadia
> 108SD/114SD

Description of Revisions:This bulletin replaces the version dated
October 2013. In Check 10, the rated output check, the acceptable
voltage difference has been changed from 0.1 V to 1.0 V.

Using the Powernet Assessment Worksheet
For all battery, charging, or starting issues:
1. Print out the Powernet Assessment Worksheet.
2. Perform each line of the Worksheet, completing the entire Worksheet even if the original issue seems to be
resolved.
3. Use the Detail section to clarify the Worksheet procedures. Every check in the Worksheet is covered in the
Detail section.
4. Once all the checks in the Powernet Assessment Worksheet have been completed, if a starting issue persists, use the Troubleshooting the Starting System section included in this document.

EPA10/EPA04 and EPA07 Vehicles have Separate Cable Voltage
Drop Checks
The alternator cables route through the starter on all vehicles except EPA07. EPA07 vehicles have a different
cable drop procedure, and their own EPA07 Path Check Worksheet.

NOTE: EPA07 vehicles with jump start posts connected to the starter can be tested using the nonEPA07 (EPA10, EPA04) vehicle procedure by placing the carbon pile clamps on the jump posts instead of the alternator. Using the jump posts will include them and their cables to the starter in the
drop test.

+

+

−

+

+

+

−
−

−

−

−

−

−

+

08/16/2013

f151181a

Fig. 1, EPA04, and EPA10 and newer: the alternator
routes through the starter. The Powernet Assessment
Worksheet includes the needed Path Check.

Freightliner Service Bulletin, February 2014

+

08/16/2013

+

f151182a

Fig. 2, EPA07: the alternator does not route through
the starter. Use the EPA07 Path Check Worksheet
instead of the Path Check portion of the Powernet
Assessment Worksheet.

Page 1

54-278
Freightliner
Service Bulletin

Powernet Troubleshooting Guide: Batteries, Path, Alternator,
and Starter
FLA COE
FLB COE
FLD Conventional
Business Class
FLC 112 Conventional

> Century Class Conventional
> Argosy COE
Cargo
> Columbia

> 122SD and Coronado
> Business Class M2
> Cascadia
> 108SD/114SD

Powernet Worksheet Detail Section (Batteries, Path, Alternator)
BATTERIES CHECK
1.

Check battery pack voltage to determine state of charge.
Charge pack to 100%. If unable, go to 3, "Break pack"

DMM (Digital Multimeter):
POS and NEG batt pack.

Rec
Value

Accept
Value
12.8V AGM
12.6V Flood

Check 1 — Check battery pack voltage to determine state of charge.
If equipped, set Load Disconnect Switch to "Off." With the DMM probes on the positive and negative posts of
the battery pack, record the voltage. Due to differences in their design and operation, flooded cell and AGM batteries have different voltages at the same state of charge.
Batteries should be fully charged before further testing. If batteries are not fully charged, they will draw current
to recharge during testing, invalidating the troubleshooting test results. Fully charged batteries ensure reliable
diagnosis.
See Table 1 for voltage as an approximate indicator of state of charge for AGM and flooded batteries.
If the battery pack will not charge to 100% state of charge, there may be a shorted cell. Break the pack into individual batteries and test individually using an approved tester. Go to Check 3, Individual Battery Testing.
After batteries have been tested individually, verify pack voltage once again.
Flooded
12.6
12.4
12.3
12.1
12
11.8

AGM
12.8
12.6
12.4
12.2
12
11.8

SoC
100%
80%
60%
40%
20%
0%

Table 1, Voltage to Approximate State of Charge
(SoC)
2.

Remove surface charge: HVAC blower, lights on, 5 min.

Check 2 — Remove surface charge: HVAC blower, lights on, 5 min.
Surface charge refers to a higher initial charge (volts), when discharging, in recently-charged batteries. This
charge is a "shallow" charge, meaning that the charging-induced chemical reaction has mostly occurred at the
surface of the lead plates, and has not equalized throughout the lead. Drawing current from the batteries before
testing removes the surface charge, allowing for a better assessment of the "deep charge" state of the lead
plates.
After the surface charge is removed, the batteries need to be at least 80% SoC for further testing. See Table 1
for voltage as an approximate indicator of state of charge.

Page 2

Freightliner Service Bulletin, February 2014

Powernet Troubleshooting Guide: Batteries, Path, Alternator,
and Starter
FLA COE
FLB COE
FLD Conventional
Business Class
FLC 112 Conventional

3.

> Century Class Conventional
> Argosy COE
Cargo
> Columbia

> 122SD and Coronado
> Business Class M2
> Cascadia
> 108SD/114SD

Break pack into individual batteries and test each with an approved battery tester.
(Remove NEG cables first!)
Replace batteries if instructed by the tester.
All batteries must pass the battery tester evaluation before troubleshooting continues.

54-278
Freightliner
Service Bulletin

Batt
Batt
Batt
Batt

1:
2:
3:
4:

PASS
PASS
PASS
PASS

or
or
or
or

FAIL
FAIL
FAIL
FAIL

Check 3 - Individual Battery Testing
Batteries should only be tested individually.
3.1 Remove the negative cables of the batteries first, and
secure the leads out of the way before touching the positive
cables. Remove the battery cables and clean the terminal
pads with a wire brush. The adapters will not make sufficient
contact with dirty or corroded contact pads.
3.2 Connect the battery tester’s positive and negative
clamps to the lead base terminal pads at the positive and
negative studs. See Fig. 3.
The threaded portion of the battery posts are not the right
place to clip: the steel threads won’t make a good
connection. The base of the post, on the lead, is the best
place to clip. Taking a few extra seconds to make sure the
tester, DMM, and carbon pile clips are well-connected can
be the difference between a useful and a useless test.

06/24/2013

f151183

Fig. 3, The lead base of the post is the best place to clip.

NOTE: If the lead base is too small to clamp to, only lead
stud adapters should be used, never nuts. The lead stud
adapters must be screwed down tight against the cleaned
lead base using a hand tool. Lead adapters are available at
most tool vendors.
Refer to the battery tester instruction manual for complete
testing instructions.
If the battery tester requires the CCA rating of the battery, it
should be on the battery label. See Fig. 4.
3.3 If the battery fails, enter the battery serial number (see
Fig. 4) and print out the result. The sensor windows on the
06/24/2013
f151184
tester and printer must be aligned to transmit the test results
to the printer.
Fig. 4, The label has the RC (reserve capacity) CCA (cold
cranking amps) and SERIAL NO. (serial number).

Freightliner Service Bulletin, February 2014

Page 3

54-278

Powernet Troubleshooting Guide: Batteries, Path, Alternator,
and Starter

Freightliner
Service Bulletin

FLA COE
FLB COE
FLD Conventional
Business Class
FLC 112 Conventional

> Century Class Conventional
> Argosy COE
Cargo
> Columbia

> 122SD and Coronado
> Business Class M2
> Cascadia
> 108SD/114SD

EPA10/EPA04: Alternator routes through starter post. Carbon pile on alternator will test alternator and
cables.
Alternator Path Check
Rec
Carbon Pile:
DMM:
Value
4a. POS alternator, GND alternator. Load at alternator-rated amps. POS alternator, POS batt pack +
4b. POS alternator, GND alternator. Load at alternator-rated amps. NEG alternator, NEG batt pack +
=

starter
Accept
Value
Total less
than 0.7 V

Checks 4a and 4b – Alternator Path Check
Setting up the Carbon Pile
Clip the Carbon Pile positive clamp on the alternator positive
post nut, and the negative clamp on the alternator body.
Reading Voltage Drop with the DMM
4a - Alternator Positive cable and connections
4a.1 Clip one lead of the DMM to the threaded portion of the
positive post on the alternator and the other lead to the positive lead base of one of the batteries. See Fig. 5.
4a.2 The battery pack should now be assembled, cables
connected, and nuts tightened 10 to 15 lbf·ft (13 to 20 N·m).
The load disconnect switch should be set to "On."

06/24/2013

f151186

Fig. 5, Alternator Positive Cable Check

4a.3 Load the system with the carbon pile to the alternator
amperage rating for 5 to 10 seconds. Record the voltage
drop shown on the DMM. The DMM should show some
voltage. If the DMM displays 0.00 V when the load is applied, there is a connection problem; check the DMM’s connections and retest.
NOTE: The alternator amp rating can be found on the
alternator, and in PartsPro. See Fig. 6.
4b - Alternator negative cable and connections
4b.1 Clip one lead of the DMM to the alternator body and
the other to the negative lead base of one of the batteries.

06/24/2013

f151187

Fig. 6, Rated amps can be found on the label.

4b.2 Load the system with the carbon pile to the alternator
amperage rating. Record the voltage drop shown on the
DMM.
Combine the voltage drop of the positive and negative cable
drop tests; the total should not exceed 0.7 V. If total voltage
drop is greater than 0.7 V, go to Check 6, then test voltage
drop again. If total drop is less than 0.7 V, go to the next
check.

Page 4

Freightliner Service Bulletin, February 2014

Powernet Troubleshooting Guide: Batteries, Path, Alternator,
and Starter
FLA COE
FLB COE
FLD Conventional
Business Class
FLC 112 Conventional

> Century Class Conventional
> Argosy COE
Cargo
> Columbia

> 122SD and Coronado
> Business Class M2
> Cascadia
> 108SD/114SD

54-278
Freightliner
Service Bulletin

Starter Path Check — EPA10, EPA04 Engines ONLY
Carbon Pile:
5a. POS alternator, GND alternator. Load at 500 amps.
5b. POS alternator, GND alternator. Load at 500 amps.

DMM:
POS starter, POS batt pack
NEG starter, NEG batt pack

Rec
Value
+
+
=

Accept
Value
Total less
than 0.7 V

NOTE: EPA07 vehicles with jump start posts connected to
the starter can be tested using this vehicle procedure by
placing the carbon pile clamps on the jump posts instead of
the alternator. Using the jump posts will include them and
their cables to the starter in the drop test.
Starter Path Check – Checks 5a and 5b – EPA10, EPA04
Setting up the Carbon Pile
Clip the carbon pile positive clamp on the alternator positive
post and the negative clamp on the alternator body. See
Fig. 7.
Reading Voltage Drop with the DMM
5a - Starter positive cable and connections
5a.1 Clip the DMM to the threaded portion of the positive
post on the starter and the positive lead base of one of the
batteries. See Fig. 8.

06/24/2013

f151188

Fig. 7, For EPA10 and EPA04 engines, the starter path can
be checked by loading the circuit at the alternator.

5a.2 Load the system with the carbon pile at 500 amps.
Record the voltage drop shown on the DMM.
5b - Starter negative cable and connections
5b.1 Clip the DMM to the threaded portion of the negative
post on the starter and the negative lead base of one of the
batteries.
5b.2 Load the system with the carbon pile to 500 amps.
Record the voltage drop shown on the DMM.
Combine the voltage drop of the positive and negative cable
drop tests; the total should not exceed 0.7 v. If total voltage
drop is greater than 0.7 V, go to Check 6, then test voltage
drop again. If total drop is less than 0.7 V, go to Check 6
but do not retest voltage drop.
06/24/2013

f151189

Fig. 8, Location of the starter positive post.

Freightliner Service Bulletin, February 2014

Page 5

54-278

Powernet Troubleshooting Guide: Batteries, Path, Alternator,
and Starter

Freightliner