This is a comprehensive guide on how to repair your 2nd Gen (2004-2009) Prius HV Battery. I will show how to take battery out, determine which blocks are weak, replace modules, restore the rest of the pack, clean copper plates, reinstall the battery.
Quick Links:
1:52 Battery Removal
12:15 Initial Voltage Measurement
14:20 Internal Resistance Test
15:48 Measure/Restore Capacity
23:11 Replacing Bad Modules
30:36 Cleaning Copper Plates
31:59 Leveling the Voltages
36:36 Battery Installation
Power supply on the video is HP DPS-600PB B 575W. It can be found on ebay for 35$ or so.
Turnigy charger on the video has been discontinued. I would try an updated version: [ Ссылка ]
Link to blank excel sheet for test results: [ Ссылка ]
Accucel-6 charger on the video: [ Ссылка ]
Replacement battery modules: [ Ссылка ]
Recommended tools:
1. Screw driver set: [ Ссылка ]
2. Sockets and wrenches set: [ Ссылка ]
3. Multimeter: [ Ссылка ]
4. Pliers: [ Ссылка ]
5. Wire cutters: [ Ссылка ]
6. Floor fan: [ Ссылка ]
Parts:
1. Alligator clamps: [ Ссылка ]
2. 16 gauge cables: [ Ссылка ]
3. Banana plugs: [ Ссылка ]
***CAUTION*** You must only work on the battery with the safety plug out. Otherwise you are in danger of electrical shock/death.
You must wear electrical safety gloves when connecting and disconnecting the terminals.
