Powernet Troubleshooting Guide: Batteries, Path, Alternator,

and Starter 54-278

FLA COE Century Class Conventional Coronado ji i

FLB COE Argosy COE Business Class M2 Freightliner
FLD Conventional Cargo > Cascadia Service Bulletin
Business Class Columbia 108SD/114SD_

FLC 112 Conventional

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 per-
sists, use the Troubleshooting the Starting System section included in this document.

EPA10/EPA04 and EPAO7 Vehicles have Separate Cable Voltage
Drop Checks

The alternator cables route through the starter on all vehicles except EPA07. EPAO7 vehicles have a different
cable drop procedure, and their own EPAQ7 Path Check Worksheet.

NOTE: EPA07 vehicles with jump start posts connected to the starter can be tested using the non-
EPAO7 (EPA10, EPA04) vehicle procedure by placing the carbon pile clamps on the jump posts in-
stead of the alternator. Using the jump posts will include them and their cables to the starter in the
drop test.

08/16/2013 #1511812 08/16/2013 1151182a
Fig. 1, EPA04, and EPA10 and newer: the alternator Fig. 2, EPAQ7: the alternator does not route through
routes through the starter. The Powernet Assessment the starter. Use the EPA07 Path Check Worksheet
Worksheet includes the needed Path Check. instead of the Path Check portion of the Powernet
Assessment Worksheet.

Freightliner Service Bulletin, September 2013 Page 1

Powernet Troubleshooting Guide: Batteries, Path, Alternator,

54-278 and Starter

i i FLA COE Century Class Conventional Coronado
Freig htliner : FLB COE Argosy COE Business Class M2
Service Bulletin FLD Conventional Cargo > Cascadia

Business Class Columbia 108SD/114SD

FLC 112 Conventional

Powernet Worksheet Detail Section (Batteries, Path, Alternator)

Rec Accept
DMM (Digital Multimeter): | Value | Value

1. Check battery pack voltage to determine state of charge. POS and NEG batt pack. 12.8V AGM
Charge pack to 100%. If unable, go to 3, "Break pack" 12.6V Flood

BATTERIES CHECK

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 bat-
teries 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.

\f the battery pack will not charge to 100% state of charge, there may be a shorted cell. Break the pack into in-
dividual 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 AGM SoC
12.6 12.8 100%
12.4 12.6 80%
12.3 12.4 60%
42.1 12.2 40%

12 12 20%
11.8 11.8 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, September 2013

Powernet Troubleshooting Guide: Batteries, Path, Alternator,

and Starter

54-278

FLA COE Century Class Conventional Coronado i i

FLB COE Argosy COE Business Class M2 Freightliner
FLD Conventional Cargo > Cascadia Service Bulletin
Business Class Columbia 108SD/114SD

FLC 112 Conventional

(Remove NEG cables first!)
Replace batteries if instructed by the tester.

3. Break pack into individual batteries and test each with an approved battery tester.

All batteries must pass the battery tester evaluation before troubleshooting continues.

Batt_1: PASS or FAIL
Batt 2: PASS or FAIL
Batt 3: PASS or FAIL
Batt 4: PASS or 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.

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
tester and printer must be aligned to transmit the test results
to the printer.

te
¥

08/24/2013 1151183

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

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So
Exievaz ie Suane ne
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06/24/2013 1151184

Fig. 4, The label has the RC (reserve capacity) CCA (cold
cranking amps) and SERIAL NO. (serial number).

Freightliner Service Bulletin, September 2013

Page 3

Powernet Troubleshooting Guide: Batteries, Path, Alternator,

54-278 and Starter

ightli FLA COE Century Class Conventional Coronado
F reig htl iner . FLB COE Argosy COE Business Class M2
Service Bulletin FLD Conventional Cargo > Cascadia
Business Class Columbia 10880/1148D

FLC 112 Conventional

EPA10/EPA04: Alternator routes through starter post. Carbon pile on alternator will test alternator and starter
cables.

Alternator Path Check Rec Accept
Carbon Pile: DMM: Value_| Value

4a. POS alternator, GND alternator. Load at alternator-rated amps. | POS alternator, POS batt pack | + Total less

4b. POS alternator, GND alternator. Load at alternator-rated amps. | NEG alternator, NEG batt pack | + 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 posi-
tive 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 Ibf-ft (13 to 20. N-m). 06/24/2013 1151186,
The load disconnect switch should be set to "On."

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 ap-
plied, there is a connection problem; check the DMM's con-
nections and retest.

NOTE: The alternator amp rating can be found on the
alternator, and in PartsPro. See Fig. 6.

06/24/2013

4b - Alternator negative cable and connections

4b.1 Clip one lead of the DMM to the alternator body and Fig. 6, Rated amps can be found on the label.
the other to the negative lead base of one of the batteries.

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 Freightiner Service Bulletin, September 2013

Powernet Troubleshooting Guide: Batteries, Path, Alternator,

and Starter 54-278

FLA COE Century Class Conventional Coronado ji i

FLB COE Argosy COE Business Class M2 Freightliner
FLD Conventional Cargo > Cascadia Service Bulletin
Business Class Columbia 108SD/114SD

FLC 112 Conventional

Starter Path Check — EPA10, EPAO4 Engines ONLY

Rec Accept
Carbon Pile: DMM: Value | Value
5a. POS alternator, GND alternator. Load at 500 amps. POS starter, POS batt pack [+ Total less
5b. POS alternator, GND alternator. Load at 500 amps. NEG starter, NEG batt pack | + than 0.7 V

NOTE: EPA0O7 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

$a - Starter positive cable and connections 06/24/2013 fo1188
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.

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 #151189

Fig. 8, Location of the starter positive post.

Freightliner Service Bulletin, September 2013 Page 5