2007 ISUZU KB P190 Workshop Repair Manual

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Page 3649 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Battery Page 6D1-3–9

8 Ensure the battery hold-down bolts (2 & 3) and bracket
(1) firmly secure the battery.
Battery hold-down bolt
torque specification ...................................8.0

Battery Page 6D1-3–9

8 Ensure the battery hold-down bolts (2 & 3) and bracket
(1) firmly secure the battery.
Battery hold-down bolt
torque specification ...................................8.0 – 10.0 Nm
9 Check the cable insulation for damage or wear along the cable. Replace the cable as required.
10 Check the cables do not have broken or frayed strands and are secure in the terminals. Repair as
required.
Figure 6D1-3 – 3
11 Ensure the terminal clamp (2) sits below the top of the battery post (1).
12 Check the terminal clamps are attached to the battery posts securely. Replace the terminals as required.
13 Tighten the terminal clamp nuts to the correct torque specification.
Battery terminal nut
torque specification .....................................2.0 – 5.0 Nm
14 Smear the battery posts and terminals with petroleum jelly to resist corrosion.
Figure 6D1-3 – 4
3.3 Hydrometer Test
As a lead-acid battery discharges, sulphur elements in the electrolyte move from the electrolyte solution into the lead
battery plates. This removes the sulphuric acid from the electrolyte and changes it to water. Therefore the concentration
of sulphuric acid in the electrolyte indicates the state of charge.
The concentration of sulphuric acid can be measured using a hydrometer. The state of charge is measured in terms of
specific gravity; the lower the specific gravity reading, the lower the state of charge.
NOTE
If distilled water has been added to the battery,
do not use the hydrometer until the battery has
been charged for at least 30 minutes.
1 Read and obey the safety precautions for working with batteries, refer to 2 Safety Precautions.
2 Remove the battery filler caps.
3 Force the air out of the hydrometer bulb.
4 Hold the hydrometer vertically in the cell with the pick-up tube submerged.
5 Draw in sufficient liquid to lift the hydrometer float freely when the bulb is fully released.

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Page 3650 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Battery Page 6D1-3–10

6 Still holding the hydrometer vertically, record the reading.
7 Put the electrolyte back into the cell.
8 Repeat steps 3 to 7 for each cell.
9 Determine the tempera

Battery Page 6D1-3–10

6 Still holding the hydrometer vertically, record the reading.
7 Put the electrolyte back into the cell.
8 Repeat steps 3 to 7 for each cell.
9 Determine the temperature of the battery by temporarily placing a thermometer (1) into one of the
cells (2).
10 Install the battery filler caps.
11 Calculate the temperature-compensated readings: add 0.004 for every 5 °C above 27 °C or subtract 0.004 for
every 5 °C below 27 °C.
12 Determine the state of charge of the battery using the temperature-compensated readings and the table
below.
NOTE
The specific gravity of a charged battery should
not vary more than 0.025 between cells. Larger
variations indicate defective cells and the battery
must be replaced, refer to 4.1 Battery.
Figure 6D1-3 – 5
Battery Condition Specific Gravity Reading
Fully charged 1.240 to 1.260
Requires charging < 1.190
Fully discharged 1.110 to 1.130
3.4 Load Test
Load testing the battery with a high rate discharge (HRD) tester simulates using the starter motor and checks if the
battery is in serviceable condition. The battery must be at least 65% charged before commencing this test.
NOTE
HRD testers are available with either fixed or
variable loads. The operating procedures may
vary from brand to brand, therefore follow the
manufacturer’s instructions.
High Rate Discharge Load Test
1 Read and obey the safety precautions for working with batteries, refer to 2 Safety Precautions.
2 Ensure the state of the battery is at least 65% charged. Refer to 3.3 Hydrometer Test.
3 Refer to W arning, Caution and Notes in this section, before disconnecting the battery.
4 Disconnect the battery negative terminal.
5 Disconnect the battery positive terminal.
6 Connect the HRD tester to the battery terminals ensuring correct polarity.
7 Set the tester switches to suit the battery size. Fixed load tester:
a Apply the load for approximately 10 seconds to remove any surface charge.
b W ait 15 seconds for the battery to recover.
Variable load tester:
a Apply a 300 A load for approximately 15 seconds to remove any surface charge.

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Page 3651 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Battery Page 6D1-3–11

b W ait 15 seconds for the battery to recover.
8 If possible, set the selector to 50% of rapid discharge current (or three times the 20 hour discharge rate).
9 Apply t

Battery Page 6D1-3–11

b W ait 15 seconds for the battery to recover.
8 If possible, set the selector to 50% of rapid discharge current (or three times the 20 hour discharge rate).
9 Apply the load test for 10 seconds and record the battery voltage. If one cell is faulty it will gas excessively or overheat. This indicates a faulty battery.
10 Recharge the battery if the voltage is at or below the minimum voltage specified by the HRD manufacturer (or 9.6 V).
11 Replace the battery if the voltage is below the minimum voltage specified by the HRD manufacturer (or below 9.6 V after the battery is charged and the test is repeated). Refer to 4.1 Battery.
12 Connect the battery positive terminal.
13 Connect the battery negative terminal.
Alternate Load Test
If HRD test equipment is not available, test the battery as follows:
1 Read and obey the safety precautions for working with batteries, refer to 2 Safety Precautions.
2 Ensure the state of the battery is at least 65% charged. Refer to 3.3 Hydrometer Test.
3 Connect a voltmeter (1) between the battery terminals.
4 Turn the headlights on to high-beam for 10 seconds to remove any surface charge from the battery.
5 Remove fuses EB11 and EB12 from the engine compartment fuse and relay housing. This prevents
vehicle ignition and fuel injection while cranking the
engine.
6 Crank the engine and read the voltmeter. At temperatures above 5°C, the voltage of a fully charged
battery should not fall below 9.6 V.
NOTE
• If the battery and engine temperatures are
below 5 °C, the voltage may fall to 9 V.
• Try to avoid activating the starter motor
continuously for more than 30 seconds. If
activating the starter motor for 30 seconds,
allow the starter motor to cool for 3 minutes.
7 Replace the battery if a cell gasses excessively or overheats or if the voltage falls away quickly.
Figure 6D1-3 – 6
3.5 Battery Current Draw Test
The following test determines if excess current is being drawn from the battery whilst the vehicle has all accessories
turned off. Excess current draw will cause the battery to go flat if the vehicle is not started for an extended period.
Test Preparation
1 Read and obey the safety precautions for working with batteries, refer to 2 Safety Precautions.
2 If the battery is flat, temporarily install a good battery for the duration of the test.
3 Ensure the vehicle starts and the accessories operate normally.
4 Ensure the theft deterrent system operates normally. Refer to 11A Immobiliser.
5 Open all the side windows for access purposes.
6 Switch the ignition off.
7 Check that all interior illumination is off, including any compartment lighting.
8 Close all doors.

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Page 3652 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Battery Page 6D1-3–12

9 Lock the doors and activate the theft deterrent system to arm the vehicle.
10 If the multimeter contains fuses, check they are serviceable.
Test Procedure
1 Switch

Battery Page 6D1-3–12

9 Lock the doors and activate the theft deterrent system to arm the vehicle.
10 If the multimeter contains fuses, check they are serviceable.
Test Procedure
1 Switch the multimeter to the mA current range (1).
2 Connect the positive test lead (2) to the fused mA terminal of the multimeter.
3 Connect the negative test (3) lead to the common terminal of the multimeter.
4 Connect large alligator clips to the ends of both test leads.
Figure 6D1-3 – 7
5 Connect the negative test lead clip to the threads of the battery negative terminal clamp (1).
6 Connect the positive lead’s clip to the threads of a convenient engine bolt (2).

Do not turn on the ignition switch while this
test is in progress. It will blow the
multimeter’s low current fuse.
7 Check the multimeter connections are secure.
8 Disconnect the vehicle’s main electrical earth by removing the battery negative terminal cable retaining
nut (3) and separating the cable from the battery
clamp.
Figure 6D1-3 – 8
9 Read the vehicle’s battery saver current on the multimeter. The multimeter reading should be within 16 – 30 mA (fluctuating).
10 If the multimeter reading is higher than specified, refer to Fault Diagnosis in this Section, otherwise restore the vehicle to its prior condition, refer to Restore in this Section.
Fault Diagnosis

Do not open any doors during this inspection.
If the doors must be opened, reinstall the
battery terminal to the battery clamp to
protect the multimeter's fuse from blowing.
Alternatively, use the higher (10 A) fuse rated
terminal on the multimeter until the source of
the higher current draw has been found.
1 Visually inspect the vehicle for illuminated lamps and components activated by energised relays.
2 If the cause of the excessive current draw is not apparent, remove one fuse (or circuit breaker) at a time to determine the circuit group that is drawing excess current. Refer to 8A Electrical Body & Chassis for fuse grouping
location.

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ISUZU KB P190 2007

Page 3653 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Battery Page 6D1-3–13

3 W hen the circuit group is determined, install the fuse / circuit breaker and identify the specific circuit within this
group that is drawing the excess current. Disconn

Page 3654 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Battery Page 6D1-3–14

4 Service Operations
4.1 Battery
Remove

Disconnection of the battery affects certain
vehicle electronic systems. Refer to 1.1
WARNING, CAUTION and NOTES before
d

Page 3655 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Battery Page 6D1-3–15

5 Install the positive terminal onto the positive battery post. Ensure the terminal sits below the top of the post and
tighten the terminal nut to the correct specificatio

Battery Page 6D1-3–15

5 Install the positive terminal onto the positive battery post. Ensure the terminal sits below the top of the post and
tighten the terminal nut to the correct specification.
Battery terminal nut
torque specification .....................................2.0 – 5.0 Nm
6 Install the negative terminal onto the negative battery post. Ensure the terminal sits below the top of the post and tighten the terminal nut to the correct specification.
Battery terminal nut
torque specification .....................................2.0 – 5.0 Nm
7 Smear the battery posts and cable terminals with petroleum jelly to inhibit corrosion.
4.2 Battery Charge
Safety Precautions
Read and obey the general safety precautions for working with batteries, refer to 2 Safety Precautions.
The battery releases an explosive hydrogen and oxygen gas mixture during charging. Ensure there are no naked flames
or sparks near the battery.
Flat batteries can be safely boost-charged, however avoid excessive charging current if the battery is more than half
charged. Slow charging is best.
Fast charging can substantially boost a battery, but slow charging is required to fully charge the battery.
Do not use a fast charger:
• for starting the vehicle,
• if the specific gravity readings are not uniform between battery cells, refer to 3.3 Hydrometer Test,
• if the specific gravity readings are above 1.20, refer to 3.3Hydrometer Test,
• if the electrolyte is discoloured with brown sediment, and
• if any of the above three conditions develop after beginning a fast charge.
Battery Charge Procedure

Disconnection of the battery affects certain
vehicle electronic systems. Refer to Warning,
Caution and Notes in this section before
disconnecting the battery.
1 Perform steps 1 to 10 of the battery inspection, refer to 3.2 Battery Inspection.
2 Remove the battery from the vehicle. Refer to 4.1 Battery.
3 If required remove the battery filler caps. Let the caps rest loosely on top of the filler tubes.

Always ensure the connections are to the
correct polarity and follow the manufacturer’s
recommendations for battery charging.
4 Connect the battery to the battery charger.
5 Set the charging current using the following table as a guide.

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ISUZU KB P190 2007

Page 3656 of 6020

ISUZU KB P190 2007 Workshop Repair Manual Battery Page 6D1-3–16

NOTE
Charging a battery at higher current rates can
significantly reduce the life of the battery.
Charge Rate Initial Current Maximum Time Required
Slow charge 4 A

Battery Page 6D1-3–16

NOTE
Charging a battery at higher current rates can
significantly reduce the life of the battery.
Charge Rate Initial Current Maximum Time Required
Slow charge 4 A 24 hours
Fast charge 35 A 2 hours
6 After a few minutes, check the colour and specific gravity of the electrolyte. Refer to 3.3 Hydrometer Test.
7 Monitor the electrolyte temperature while the battery is charging. If the electrolyte temperature reaches 55 °C:
a switch the charging current off,
b allow the battery to cool,
c reduce the charging current, and
d restart charging the battery.
NOTE
For the best results, charge the battery with the
electrolyte and plates at room temperature. An
extremely cold battery may not appear to accept
current for several hours after starting the battery
charger. If the battery does not appear to accept
charge after several hours replace the battery.
8 For slow charging check the voltage and specific gravity each hour or more regularly for fast charging. Stop the charging when there is no change in voltage or electrolyte specific gravity over three checks.
9 If the battery was fast charged connect the battery to a slow-charger for a few hours to bring the battery to the fully charged condition. Ensure the last few hours of charge do not exceed 1 A.
10 Tighten the filler caps. Ensure they are secure.
11 Install the battery in the vehicle. Refer to 4.1 Battery.
4.3 Emergency Jump Starting Procedure
Safety Precautions
• Read and obey the general safety precautions for working with batteries, refer to 2 Safety Precautions.
• Do not allow the vehicles to touch each other during the jump starting procedure.
• Ensure the assisting vehicle battery has the same voltage rating and connects negative to ground. If this is not the
case, serious injury and damage to electrical equipment can result.
• Do not push or tow the vehicle to start it. Damage can result when unburnt fuel reaches the catalytic converter and
ignites.
• Do not start the vehicle using a fast charger.
• W hen using jumper leads, treat both the booster battery and the discharged battery with care.
• Do not allow sparks, flame or smoking near the battery.
• Ensure that metal tools or jumper cables do not simultaneously contact the battery positive terminal and any other
metal part of the vehicle.
Jump Starting Procedure
1 Position the assisting vehicle so the batteries of both vehicles are close together, refer to Figure 6D1-3 – 10.
2 Apply the park brake on both vehicles.
3 Ensure that P (park) is selected for automatic transmission and N (neutral) is selected for manual transmissions.

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