ABS, SUB TANK, AIRBAGS & ALTERNATOR lights flickering - BATTERY explosion - ZD30DI

[Deon Kruger]

Bigrig,

Actually no, I only know of one guy with the same name as me and that I picked up via the internet.

I will update once sorted. At least I now have a mech that knows his stuff.

Cheers.
Deon.

[xtreme patrol]

Totally agree with everyone's diagnosis
It has to be the alternator as the exact same thing happend to me I unfortunately ignored the warning that the alt was going bad as the headlights started to go bright and i mean really bright then dim again then one day driving along and all the lights on the dash started to go crazy the instrument cluster filled with smoke and she died. My near new battery swelled like a balloon and was ready to pop.
All up i needed to replace the ECU, ALT, Airflow meter, instrument cluster, stereo, all globes inside and out, most fuses, power antenna and my central locking is still not working and i need a new airbag control box.
Auto elec said something fused inside the alternator and it sent something like 24 volts to everything

Hope it works out better for you than it did me
Cheers

[the evil twin]

Sounds like you have experienced a classic case of thermal runaway... bleeping dangerous things Lead Acid batteries if subjected to high temps and overcharging.

If you are battling hot engine bays it is well worth keeping a very close eye on the battery electrolyte levels and check the Alternator output as soon as you get the truck going again.

[Ben-e-boy]

Sounds like you have experienced a classic case of thermal runaway... bleeping dangerous things Lead Acid batteries if subjected to high temps and overcharging.

If you are battling hot engine bays it is well worth keeping a very close eye on the battery electrolyte levels and check the Alternator output as soon as you get the truck going again.

I agree with thermal runaway. its a terrible thing
last time I dealt with that (not on a car) I had a motor circuit breaker blow up in my face. I worked out the perspective fault current to be 65000 amps if it wasnt for ppe I would be in a great deal of pain

[Deon Kruger]

From the conversation I picked up that batteries explode. Seems to be a spark between plates causing the nitrogen gas to explode. I am utilizing Bosch sealed batteries. As far as I understand the electrolyte levels should not go below the plates.

On my second larger battery (ALSO A SEALED BOSCH SILVER CALCUIM) I saw small drops of acid spray on the side of the engine bay. Seems to be omitted via a small vent on the battery. If this is the case and logic prevails then the electrolyte level might be to low as well, hence another possible explosion.

As this is a sealed battery how do I confirm the electrolyte level?

[YNOT]

Batteries emit hydrogen not nitrogen - nitrogen is an inert gas.
Silver calcium sealed batteries are a wet cell battery. They are designed to self regulate electrolyte levels however if they are badly over charged they can still pump water and acid out the vent as you have seen. You have no way of checking electrolyte levels on most sealed batteries.
Have you had the alternator checked yet?

Tony

[the evil twin]

Batteries emit hydrogen not nitrogen - nitrogen is an inert gas.
Silver calcium sealed batteries are a wet cell battery. They are designed to self regulate electrolyte levels however if they are badly over charged they can still pump water and acid out the vent as you have seen. You have no way of checking electrolyte levels on most sealed batteries.
Have you had the alternator checked yet?

Tony

What Tony said X 2... Valve regulated batteries can still dump electrolyte but theres nothing you can do about replacing it.

"Maint Free" batteries are very convenient but do not last as long as a properly maintained equivalent (I stress equivalent) lead acid battery. The Maint Free is popular because hardly anyone maintains their battery correctly, present forumites excluded of course, and therefore the Maint Free is percieved to be better and longer lasting than a poorly maintained traditional battery.

A traditional battery can have the correct amount and ratio of electrolyte and also chemically reconditioned. The raft of smart chargers such as the Ctek's etc these days attack sulphation and other issues by 'electrically' reconditioning the battery. Certainly works but not quite as well, however there is no other option on a sealed battery.

I probably confused the issue with my prev post so apologies for that...

Bottom line is Lead Acids explode a lot more often than is commonly reported. Under charging just makes them useless, Over charging, significant over charging that is, whilst a lot less prevalent can easily cause them fail catastrophically IE blow up

[Yendor]

Hey Deon.

How's your baby going?, is it back on the road yet?

Cheers Rodney