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 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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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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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. Disconnect the wiring harness connectors in this circuit group one at a
time. Refer to 8A Electrical Body & Chassis.
4 W hen the cause is disconnected, the multimeter reading should drop to the correct reading as outlined in Step 9 of the Test Procedure in this Section.
5 If required, remove the components in this circuit one at a time to determine the cause of the excessive standing current. Refer to 8A Electrical Body & Chassis.
6 Repair the fault, refer to 8A Electrical Body & Chassis.
7 Ensure any fuses, circuit breakers and connectors that have been removed are secure.
Restore
1 Reconnect the electrical earth cable to the battery terminal and tighten the nut to the correct torque specification.
Battery terminal nut
torque specification .....................................2.0 – 5.0 Nm
2 Disconnect the multimeter connections.

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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
disconnecting the battery.
1 Read and obey the safety precautions for working with batteries, refer to 2 Safety Precautions.
2 Disconnect the negative battery terminal (1).
3 Disconnect the positive battery terminal (2).
4 Remove the battery hold-down bolts (3 & 4) three places, and the battery hold-down bracket (5).
5 Lift the battery out of the engine compartment.
Figure 6D1-3 – 9
Reinstall
NOTE
Before installing a used battery perform steps 1
to 10 of the battery inspection, refer to 3.2
Battery Inspection.
1 Ensure the battery tray, cables and terminals are clean and free from corrosion and moisture.
2 Ensure that no foreign objects such as loose nuts or stones are located in the battery tray.
3 Place the battery onto the battery tray and ensure the battery sits level.
4 Install the battery hold down bracket and tighten the bolt to the specified torque. Battery hold-down bolt
torque specification ...................................8.0 – 10.0 Nm

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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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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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Battery Page 6D1-3–17

4 Turn off the ignition, lights and all other electrical loads.
5 Check the battery filler caps on both batteries are tight.
6 Place a wet cloth over the battery filler caps of each battery.
7 Attach one end of the red jumper cable to the positive terminal of the booster battery.
8 Attach the other end of the same cable to the positive terminal of the discharged battery.
9 Attach one end of the black jumper cable to the negative terminal of the booster battery.
10 Attach the other end to a solid stationary, metallic point on the engine of the disabled vehicle.
NOTE
Do not connect this end directly to the negative
post of the discharged battery.

Figure 6D1-3 – 10
Legend
Order of hook-up:
1 Booster vehicle, positive terminal
2 Disabled vehicle, positive terminal
3 Booster vehicle, negative terminal
4 Disabled vehicle, engine ground point Booster vehicle
Disabled vehicle

11 Ensure the jumper cables are not on or near drive pulleys, cooling fans or other points that will move when the engine is started.
12 Start the engine in the booster vehicle and run the engine at a moderate speed for a few minutes.
13 Start the engine in the disabled vehicle.
NOTE
If the engine in the disabled vehicle does not start
within 30 seconds, stop cranking the engine and
fix the cause. Refer to 3 Diagnosis.
14 W hen the engine starts, allow both engines to idle for approximately seven minutes. This allows the voltage levels in both vehicles to balance.
15 Leave the vehicles running and remove the jumper cables in the reverse sequence to attaching them. W hen removing each clamp, take care to ensure that it does not touch any other metal.
16 Discard the wet cloths covering the battery filler caps of both batteries.

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Battery Page 6D1-3–18

4.4 Dry Charged Batteries
Storage
Dry charged batteries are fully charged when manufactured and contain no electrolyte until activated. The dry charged
can be stored indefinitely with no servicing until activated.
Activation
1 Remove the battery filler caps.
2 Add 1.265 specific gravity electrolyte to each cell to the correct level.
3 W ait several minutes.
4 Check the electrolyte level and add more electrolyte (not water) as required. After a dry charged battery is activated, it becomes a wet battery.
Post Activation Tests
Although a dry charged battery can be put into service immediately after activation, the following tests are recommended:
1 Check the voltage of the battery after adding the electrolyte.
2 If the reading is less than 10 V, replace the battery.
3 Check the specific gravity of the electrolyte in each cell, refer to 3.3 Hydrometer Test.
4 If any reading shows more than a 0.030 drop from the initial electrolyte reading, slow-charge the battery before use. Refer to 4.2 Battery Charge.
5 Check the cells for violent gassing. If violent gassing is detected evenly across all cells, slow-charge the battery before use. If violent gassing is not even across all cells, replace the battery.

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Battery Page 6D1-3–19

5 Specifications
Rated Voltage ................................................................................................................... 12 V
Cold Cranking Amps ........................................................................................ 430 A minimum
Reserve Capacity ....................................................................................85 minutes minimum
20 Hour Discharge ...................................................................................55 A / hour minimum
5 Second Voltage @ 25 °
C .................................................................... 150 A 10.4 + / – 0.2 V
................................................................................................................. 400 A 8.4 + / – 0.2 V
Number of Plates (per cell) ................................................................................................... 1 1
NOTE
Specified ratings when tested in accordance with
Australian Standard AS 2149-1990

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Battery Page 6D1-3–20

6 Torque Wrench Specifications
Battery Hold-Down Bolts ............................................................. 8.0 – 10.0 Nm
Battery Terminal Nut...................................................................... 2.0 – 5.0 Nm

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