Sudden loss of electrics and flat battery when driving

[woody]

G'day all,
Just probing the collective knowledge to see if anyone can shed some light on my problem.

Driving home from a camping trip to Wivenhoe Dam in "The Mistress" ('97 300tdi wagon) and towing the camper trailer. I had a sudden and instant loss of electrical power shutting down the engine. No instruments, radio, lights or other signs of life.


On inspection of the engine bay fuses the second fuse (60 amp) from the front of the vehicle had blown. (did not replace)
The main battery was extremely hot and flat
Aux battery appeared to be ok and powering the fridge in the back.
Checked all circuit breakers and other fuses

So now I did something that I feel I may regret, I disconnected and removed the main battery and swapped the leads over to the aux battery then tried to start the engine. The engine started, ran for about 10 seconds and shutdown in a repeat performance resulting in another very hot and flat battery and leaving me to scratch my head on the side of the road in 40+ degree temparetures.


woody

[jboot51]

Has to be a short circuit. To heat up the battery, thats massive amps, not too many cables can handle a high current without melting.
Starter motor works, so it's not that
could be the alternator has died and shorting out.
maybe winch control box if you have one.

Would have thought a 300 TDI would keep going regardless.

[Blknight.aus]

my money is on a shorted main cable near the fuse panel or a shot alternator/lead.

[Loubrey]

.

Would have thought a 300 TDI would keep going regardless.

Electric fuel pump on that one. No power, no fuel

[woody]

my money is on a shorted main cable near the fuse panel or a shot alternator/lead.

I'll give it the once over tomorrow, but it better bloody not be the alternator lead as I recently (12 months ago) had the leads from the alternator through to and including the battery box replaced and upgraded.

thanks

woody

[Blknight.aus]

That means it might turn out to simply be a dropped locating bolt in the fuseable link section.

Is the vehicle back in the switch yet?

If so I can make a swing out with the meter and some gear to have a look see, but in the mean time head to super cheap and grab youself some replacement fuses.

[DeanoH]

Has the main battery failed and is dragging the other down ? With a massive battery discharge like you have, look for smoke and/or heat. perhaps the main battery has shorted cells. ? Did you disconnect the original main battery when you swapped batterys over ?

Deano :)

[woody]

Has the main battery failed and is dragging the other down ? With a massive battery discharge like you have, look for smoke and/or heat. perhaps the main battery has shorted cells. ? Did you disconnect the original main battery when you swapped batterys over ?

Deano :)

no smoke, plenty of heat, main battery completely removed, both batteries seem to have charged back up to normal.

thanks

woody

[jplambs]

That means it might turn out to simply be a dropped locating bolt in the fuseable link section.



I'm with Dave, I had something similar happen to a landcruiser ute on the farm, only difference was I could get things working again if I jiggled the leads. Turned out to be a dodgy fuseable link. The symptoms I had were almost identical.

JP

[woody]

Eureaka! I found it!

It seems that when the winch was fitted they routed the cable behind the turbo air intake and bolted it onto the starter solenoid. As a consequence the vibration caused the cable insulated to wear and short out.

http://imageshack.us/a/img802/4189/imag0233o.jpg
http://imageshack.us/a/img5/961/imag0239r.jpg
http://imageshack.us/a/img233/1497/imag0242mm.jpg

I'm still checking the rest of the wiring for signs of wear but I'll bite the bullet and sought out the battery box once and for all.

Thanks for the advice and offers for assistance, much appreciated.

woody

[flagg]

Make sure you fit flexible conduit on your new cable so it doesn't happen again :)

[woody]

Make sure you fit flexible conduit on your new cable so it doesn't happen again :)

ironic that it was the only cable not in conduit.

[Blknight.aus]

let me know if you want a better cable made up or need to recrimp that one.

[woody]

Thanks again for the offer Dave, hopefully I can scrounge enough from what I have here.

woody

[Blknight.aus]

bring it over and I'll sheath it up for you, Heatshrink and conduit to spare thanks to some help from other forum members

[woody]

Finally completed the battery box, my hat goes of to all that do this for a living, you won't have any competition from me :p

https://www.aulro.com/afvb/

http://imageshack.us/a/img707/4131/imag0247i.jpg

http://imageshack.us/a/img194/8494/imag0249mi.jpg

A big job and I don't mind admitting that on more than one occasion I though I'd bitten off more than I could chew.

thanks again for the advice and offers for help

woody