Difficulty

Moderate

Steps

5

Time Required

                          15 - 20 minutes

Sections

1

  • Battery pack
  • 5 steps

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  • BackBosch Akku Bohrschrauber PSR 9.6 VE 2

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Introduction

Because the drill came with two battery packs, it may be possible to put together one good pack out of two bad ones by combining good cells from both packs.

The printing on the cells tells us they are NiCad - using different cells could impede the packs’ efficiency and robustness.

What you need

Step 1

              Remove the screws and lift the lid
  • Loosen and remove the four screws with a Torx T 10 screwdriver (in a pinch you can use a flat screwdriver).
  • One of the screws is secured by a 3 mm high green cap (green marker) . I used a small screwdriver to pry it free, regrettably not without some scratches.
  • While pressing the red locking tabs remove the upper part from the lower part.

Loosen and remove the four screws with a Torx T 10 screwdriver (in a pinch you can use a flat screwdriver).

One of the screws is secured by a 3 mm high green cap (green marker) . I used a small screwdriver to pry it free, regrettably not without some scratches.

While pressing the red locking tabs remove the upper part from the lower part.

1024

Step 2

              Remove the battery pack
  • Remove the red tabs by pressing them in, the metal springs may drop out of their positions but are easy to reposition.
  • Carefully remove the 8 cell battery pack.

Remove the red tabs by pressing them in, the metal springs may drop out of their positions but are easy to reposition.

Carefully remove the 8 cell battery pack.

Step 3

              Measure the cell voltage
  • Take a picture of the cells’ layout for reassembly.
  • Remove the foam rubber underneath the cells.
  • Now you can remove the spacer between the 7 cell-hexagon and the one upper remaining cell.
  • Measure the voltage from each individual cell, the reading should be upward from 0.8 V, if not the cell is broken and has to be replaced.
  • You’ll need 8 working cells… Good luck !

Take a picture of the cells’ layout for reassembly.

Remove the foam rubber underneath the cells.

Now you can remove the spacer between the 7 cell-hexagon and the one upper remaining cell.

Measure the voltage from each individual cell, the reading should be upward from 0.8 V, if not the cell is broken and has to be replaced.

You’ll need 8 working cells… Good luck !

Step 4

              Removal of working cells and reassemble together
  • the (welded?) connections between the cells can be pried off as best as possible with a flat screwdriver and then separated with pliers
  • Make sure that the cells can be connected as well as possible by soldering them together afterwards. Soldering is done at a high temperature because the heat dissipates quickly. If necessary, a wire must be soldered in between.
  • Pay attention to the polarity (but it’s actually clear)
  • Carefully detach the head with the connectors and the thermal resistor and reassemble correctly after assembly

the (welded?) connections between the cells can be pried off as best as possible with a flat screwdriver and then separated with pliers

Make sure that the cells can be connected as well as possible by soldering them together afterwards. Soldering is done at a high temperature because the heat dissipates quickly. If necessary, a wire must be soldered in between.

Pay attention to the polarity (but it’s actually clear)

Carefully detach the head with the connectors and the thermal resistor and reassemble correctly after assembly

Step 5

              Reassemble and charge
  • Measure the total voltage of the assembled cells. It should be 7V or more.
  • Reattach the foam rubber, align using the cells’ imprint on it.
  • Put back together in de plastic packholder. Charge a few times. I had to charge the pack three times until I had an acceptable amount of stored energy. But the drill works again.

Measure the total voltage of the assembled cells. It should be 7V or more.

Reattach the foam rubber, align using the cells’ imprint on it.

Put back together in de plastic packholder. Charge a few times. I had to charge the pack three times until I had an acceptable amount of stored energy. But the drill works again.

To reassemble your device , follow the steps in reverse order.

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