2007 ISUZU KB P190 battery

Battery Page 6D1-3–3

1 General Information
The vehicle is fitted with a 12 V battery located in the front right-hand corner of the engine compartment. The battery
provides:
• power for cranking the engine,
• power for a limited time when the electrical load exceeds the generator output,
• power for the accessories when the engine is not running, and
• a voltage stabilising load for the electrical system.
1.1 WARNING, CAUTION and NOTES
This Section contains various W ARNINGS, CAUTIONS and NOTE statements that you must observe carefully to reduce
the risk of death or injury during service, repair procedures or vehicle operation. Incorrect service or repair procedures
may damage the vehicle or cause operational faults. W ARNINGS, CAUTION and NOTE statements are not exhaustive.
HOLDEN LTD can not possibly warn of all the potentially hazardous consequences of failure to follow these instructions.
Definition of WARNING, CAUTION and NOTE Statements

Diagnosis and repair procedures in this Section contain both general and specific W ARNING, CAUTION and NOTE
statements. HOLDEN LTD is dedicated to the presentation of service information that helps the technician to diagnose
and repair the systems necessary for proper operation of the vehicle. Certain procedures may present a hazard to the
technician if they are not followed in the recommended manner. W ARNING, CAUTION and NOTE statements are
designed to help prevent these hazards from occurring, but not all hazards can be foreseen.
WARNING defined
A W ARNING statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in death or injury. A W ARNING statement alerts you to take necessary action or not to take a
prohibited action. If a W ARNING statement is ignored, the following consequences may occur:
• Death or injury to the technician or other personnel working on the vehicle,
• Death or injury to other people in or near the workplace area, and / or
• Death or injury to the driver / or passenger(s) of the vehicle or other people, if the vehicle has been improperly
repaired.
CAUTION defined
A CAUTION statement immediately precedes an operating procedure or maintenance practice which, if not correctly
followed, could result in damage to or destruction of equipment, or corruption of data. If a CAUTION statement is ignored,
the following consequences may occur:
• Damage to the vehicle,
• Unnecessary vehicle repairs or component replacement,
• Faulty operation or performance of any system or component being repaired,
• Damage to any system or components which depend on the proper operation of the system or component being
repaired,
• Faulty operation or performance of any systems or components which depend on the proper operation or
performance of the system or component under repair,
• Damage to fasteners, basic tools or special tools and / or
• Leakage of coolant, lubricant or other vital fluids.
NOTE defined
A NOTE statement immediately precedes or follows an operating procedure, maintenance practice or condition that
requires highlighting. A NOTE statement also emphasises necessary characteristics of a diagnostic or repair procedure.
A NOTE statement is designed to:

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Battery Page 6D1-3–4

• Clarify a procedure,
• Present additional information for accomplishing a procedure,
• Give insight into the reasons for performing a procedure in the recommended manner, and / or
Present information that gives the technician the benefit of past experience in accomplishing a procedure with greater
ease.
1.2 Battery Terminals and Cables
The cables attached to the battery posts provide power and ground connections for the vehicle electrical system. These
battery cables attach to the battery posts via nut-tightened terminals. The battery is held in position by a hold-down
bracket and bolts. Refer to Figure 6D1-3 – 1.

Figure 6D1-3 – 1
Legend
1 Negative Battery Post
2 Negative Battery Terminal
3 Negative Battery Terminal Bolt
4 Negative Battery Terminal Nut
5 Positive Connection Cover
6 Battery Positive Cable Nut 7 Battery Positive Cable Assembly
8 Battery Fuse Box Nut
9 Battery Fuse Box Washer
10 Main Fuse Box Supply
11 Positive Battery Terminal
12 Positive Battery Terminal Nut 13 Positive Battery Terminal Bolt
14 Positive Battery Post
15 Battery Positive Cable Assembly
16 Battery Positive Cable Assembly
17 Battery Hold Down Bracket
18 Battery Hold Down Bolts
19 Battery Hold Down Bolt
1.3 Battery Ratings
There are two battery ratings to consider when replacing a battery, reserve capacity (RC) and cold cranking amps (CCA).
Ensure the replacement battery meets or exceeds these rating specifications.
Reserve Capacity
The RC of a battery is the amount of time (measured in minutes) the vehicle will travel at night with minimum electrical
load and no generator input.

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Battery Page 6D1-3–5

This time is measured as the time taken for the battery voltage to reduce to 10.5 V from the following initial conditions:
• a fully charged battery at 25 °C, and
• discharged at a constant current of 25 A.
Cold Cranking Amps
The CCA rating indicates the ability of the battery to maintain enough voltage for ignition requirements while supplying
engine cranking current for long enough to start the engine under severely cold conditions.
The rating is the minimum amperage maintained when the engine is cranked for 30 seconds. The battery must maintain
at least 7.2 V at 18 °C.
Ratings
A specification label on the top of the battery displays the original equipment part number.
All vehicles are fitted with a low maintenance, 85 minute RC and 430 CCA battery.

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Battery Page 6D1-3–6

2 Safety Precautions

• Battery fluid contains sulphuric acid,
which can cause serious injury. Do not
allow liquid from the battery to contact
eyes or skin. If contact occurs, flush the
area immediately with running water and
contact a physician.
• Lead acid batteries produce explosive
gases. Keep sparks, flames and lighted
cigarettes away from the battery,
especially when the battery is being
charged. Failure to follow this warning
could result in a battery explosion.
• Metal objects that touch a battery terminal
can produce sparks that can cause
serious burns. When working near a
battery, take extra care with metal objects
including tools and items of jewellery,
especially rings and metal watchbands.

Do not allow liquid from the battery to contact
clothing or painted surfaces. If contact occurs,
flush the area immediately with running water.
W hen working with or near the battery, always:
• W ear safety glasses and work gloves.
• Remove items of jewellery such as rings and metal watchbands.
• Ensure the ignition is switched off when connecting or disconnecting battery cables, battery charging equipment or
battery jumper cables. Failing to do so can damage the vehicle electronic components.
• Disconnect the negative battery cable before disconnecting the positive cable from the battery. Inversely, connect
the positive battery cable to the battery before connecting the negative cable. This reduces the possibility of
shorting the battery to ground while working near the positive connections.

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Battery Page 6D1-3–7

3 Diagnosis
3.1 Diagnostic Procedures
Introduction
This test is used to aid in diagnosing faults with the vehicle where the battery seems to be at fault.
W ith the increased use of electronic sensors and computer control, the battery is much more than just a component used
to start a car. Low battery voltage can:
• affect the operation of the vehicle control modules and cause driveability problems, and
• cause the control modules to set diagnostic trouble codes (DTCs).
For example if a control module senses low battery voltage, it may increase fuel injector timing to increase engine rpm to
increase the generator output.
Therefore consider the state of charge of the battery any time a customer complains of a driveability related problem.
Test Description
The following numbers refer to the step numbers in the diagnostic table:
1 Checks the operator understands the safety precautions for working with batteries.
2 Checks if the vehicle is fitted with a battery of the correct specification.
3 Checks if the battery appears serviceable by performing the battery inspection procedure.
4 Checks if the battery loses charge over an extended period. If so the likely problem is excess current draw while the vehicles ignition is in the off position.
5 Checks the state of charge of the battery.
6 Checks if the battery is capable of delivering the required load by performing the load test procedure.
Diagnostic Table Notes
1 For all wiring harness fault diagnosis, refer to 8A Electrical Body & Chassis.
2 For wiring harness repairs, refer to 8A Electrical Body & Chassis.
3 Refer to 6D1 – 3 Battery – V6.
Diagnostic Table
Step Action Yes No
1
Have you read and understood the safety precautions for working with
batteries? Go to Step 2 Refer to 2
Safety Precautions
2 Check the battery fitted is the correct specification recommended for
the vehicle? Refer to 5 Specifications.
Is the battery the correct specification? Go to Step 3 Replace the battery
with the correct
specification
3 Perform the battery inspection, refer to 3.2 Battery Inspection.
Does the battery appear serviceable? Go to Step 4 Replace the battery,
refer to 4.1
Battery
4 Does the customer complain the battery loses charge if the engine is
not started for an extended period? Preform the battery
current draw test, refer to 3.5
Battery
Current Draw Test Go to Step 5

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Battery Page 6D1-3–8

Step Action Yes No
5
Perform the hydrometer test, refer to 3.3 Hydrometer Test.
Is the battery fully charged? Go to Step 6 Fully charge the
battery, refer to 4.2 Battery
Charge
6 Load test the battery, refer to 3.4 Load Test.
Does the battery pass the load test? Battery Serviceable.
Refer to:
6D1–1 Charging System – V6. Replace the battery,
refer to 4.1
Battery
When all diagnosis and repairs are completed, check the system for correct operation.
3.2 Battery Inspection
1 Read and obey the safety precautions for working with batteries, refer to 2 Safety Precautions.
2 Check the battery terminals and around the battery area for corrosion deposits. Remove any deposits as follows: a Scrub the area with a stiff brush.
b Treat the area with a solution of warm water and baking soda or ammonia.
c Rinse with clean water.
3 Check the battery posts, if they are loose, burned, pitted or damaged in any way replace the battery. Refer to 4.1 Battery.
4 Check the battery case, if it is cracked or damaged replace the battery. Refer to 4.1 Battery.
5 Remove each filler cap (1) and check the electrolyte level is at the bottom of the filler-neck tube (2).
6 If the level is low, carefully add distilled water to the cell until the level reaches the bottom of the filler-neck
tube.
NOTE
Do not overfill the cells, but maintain the level at
least 20 mm above the separator plates (3).
7 If the electrolyte usage seems excessive, check the battery case is not faulty.
NOTE
Normal electrolyte usage is less than 30 ml per
10,000 kilometres (or slightly more for long,
continuous running or in high temperatures).
Figure 6D1-3 – 2

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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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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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