DeWalt FlexVolt Battery Pack Look Inside (Video #1)

[@jonathanridder]

Great job figuring out this strange battery system. One thing that this system allows DeWalt to do is ship the batteries on airplanes with less restriction. The shipping clip that comes with the battery separates it into three disconnected 2.0Ah batteries (it pushes the sliding switch in half way) so the wattage of each one is less than the allowed maximum.

[@johnhill3504]

Good explanation yes please on the repair video I have one of these and you never know when I will need to repair it thanks for your work

[@brentjohnson6654]

I would love to see the repair of this.

[@TranTek]

yes taking it apart is tough ripping everything out i had one was going to do it but got busy

[@WTButtonDo]

Would love to see a repair. Im having a problem were the battery is showing 3 bars of power but isnt working in the tool.

[@ianmurray3820]

Definitely love to see this thing come apart but even better see it go back together without melting any pliers or cutters…..don’t ask me how I know these high density batteries can melt tools..😂😂😂

[@nrrn4454]

Thanks for the layout

[@carlosorellana200]

Can you do a video in an Dewalt 9.0 battery? The pack assembly is a different from the 6.0.

[@ThriftyToolShed]

If I come across one I sure will. Thanks for your comment.

[@JohnWick-yt6rv]

Yes! Battery video!

[@silverado2500wr450]

I have a 40v DeWalt lithium ion battery. Wouldn't charge. Indicated 28 v on the multimeter. I tried the typical jump starting. Voltage went up to about 32 volts, but charger still wouldn't turn on. And I noticed as soon as I put it in the charger, it wouldn't "test" it first. Just immediately said no good. I took it apart and took some voltage measurements. Got different readings from different spots. I realized after examining it, there is a fuse or fusible link at the front. Testing on both sides would show 32v and 35v. Looked closer at the fuse, and it is apparently broken. Guess it's making some contact. I just bypassed the fuse temporarily to see what would happen. Put it in the charger and it started charging. Wondering if you've seen this before. And if possible where I can get a fuse for it . Have looked everywhere and can't find one. Looks similar to a bolt on Bussmann 70a fusible link. Thanks

[@ThriftyToolShed]

I have not worked on the 40V DeWalt packs. I have had fuses blow on EGO 56V 5Ah packs before. Not the same style fuse though. I used a fuse link strip and soldered it in place on the EGO. Not sure if it would work for the 40V or not? Similar to these? amzn.to/3yl4okI

[@silverado2500wr450]

@@ThriftyToolShed thanks for the response. I'll have to find something similar. It looks like a bolt on one, but where the holes are at each end of the copper tabs, there are heat shrink tabs melted over the holes, and the wires are soldered to each end of the fuse.

[@iphlueable]

Where can I get replacement plastic parts for this battery? Outer shell in other words...?

[@ThriftyToolShed]

Other than eBay, I would not know of anywhere. The only other way would be if lucky 0 enough to find a bad one in the recycle bins at Lowe's, Home Depot or some other location that may have an out in the open battery recycle bin?

[@songgao3503]

This diagnosis method is very effective. I have a 54v battery cannot be charged. After opening it, I found that a battery leaked, but after I replaced it, I found that it still could not be charged. The meter showed that the two interfaces of B- and ID were used. The resistance is 0Ω, please let me know is anyting i can do for this.

[@songgao3503]

and i was doing test with good battery,B- and ID show 600Ω

[@ThriftyToolShed]

I am not sure your brand here. Still if 600 ohm is good battery then I would see if you can trace out on the BMS board of this goes to a resistor or thermistor that could be the issue.

[@ThriftyToolShed]

I also have a ECHO 58V pack repair video and I had to reset the microcontroller on the BMS for it to work correctly. You may want to watch it and see if it's similar issue to yours.

[@songgao3503]

@@ThriftyToolShed ye,brand was dewalt and sell in australia, is almost same with you fix in de vido, I can not measure the components on the motherboard, they are all sealed by glue. Hope I can find inspiration in your other videos, the video you made is very useful.

[@ThriftyToolShed]

@song gao Yes, this pack also had a 600 ohm resistor on the board it had a marking of 76A, I read this by sticking my fine needle tip leads through the silicone potting and checking it! This potting can be removed but it seems more difficult to remove than the EGO 56V potting was. I showed the potting removed on this video. kzbin.info/www/bejne/e3mTeIZmnrqtsK8

[@keemazon2004]

Please do I have 2 batteries that are not working

[@nguyendangminhn]

where is number #2?

[@ThriftyToolShed]

kzbin.info/www/bejne/eqqkiKNsn76hgs0 The video got out of order because of a KZbin upload issue. The last few minutes of the video would freeze and it had to be uploaded again after I realized the issue.

[@staginglightingsensation8505]

Easy replacement just take your time and maybe take pictures just incase

[@LilasTools]

👍

[@jdmccorful]

Good common sense explanation about operation. Yes, would be interested in seeing repair. Thanks for the look.

[@ThriftyToolShed]

Awesome, thanks for your comment!