Repairing a Bad Cell in a Dewalt 60v Battery
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- Опубліковано 19 січ 2025
- Had a DeWalt 60v Battery go bad, a tear down discovered that one cell was bad, so I called Dewalt and they sent me a replacement, now I still have a bad battery. So why not try to fix it?! Purchased another 18650 lithium cell to replace the bad one in the pack. Soldering proved to be a little tricky, but seems to be working.
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If you're going to solder these the best way is to use flux on the cell and put a bead of solder on the cell first. Then use the soldering iron to push the wire/nickle strip down onto the solder. Also 18650s have a huge variable range of capacity and output, its important to get the same battery make/model if possible. The best way to attach the nickel strips is a spot welder, that is how the factory does it.
I'll have to remember that for next time (if there is), unfortunately I don't have a spot welder, for all the times I could use one I should look at getting one!
Bigger solder tip would make a big difference. Solder on the cell "first" to put a contact pad, then put the silver tab down on the solder and reflow.
Scuff the cells is actually a bad idea as you are removing the silver coating off the steel shell. This will allow oxidation if all the steel isn't re-sealed. Use some really good flux to clean the surface.
Soldering on a lithium cell the contact needs to be far less than 30seconds. More like 5 seconds max.
Yep should have had a bigger iron mine is right on the edge of what they recommend
Spot weld is the preferred method
30 seconds is a joke.
2-3 seconds
Mini spot welder works a lot better on those.
That one is not mini?
The original cell is a samsung 20S.
The one you put in was a Sony VTC5.
Both are good cells, but the mismatch was a huge mistake... i bet that pack no longer functions
If you attempt this repair, you need to be aware that installing a new cell, will likely cause the pack to fail. The cells should be balance by capacity as well. One last thing, the cells should be the same when being used in a high current drawing system. Not sure what sony cell you used, but the blue samsung cells that are in that pack are 30A discharge cells. Depending on the Sony you used, it may not be able to drain that amount of current, which will lead to overheating in that cell.
I think he just replaced a 30A 2000mAh cell with a 20A 2600mAh cell. I agree, not a great idea.
@@thehhoff69 I agree that is a vtc5 ... I believe that is a 20a max draw battery.
@@thehhoff69 it was Samsung 20r in stock 22A current - replaced, vtc5 has almost same specs, and almost same inner resistance, so +- it’s should by fine, but no voltage balance it’s real bad in this situation
@@kor_nellione I am going to respectfully disagree. A Samsung 20R is a teal wrapped cell, the blue wrapped cells in these packs are the 30A Samsung 20S. I also would not say that they have "almost the same specs", the VTC5 is a 2600mAh cell while the 20S (and 20R for that matter) are 2000mAh. I have to think that is going to cause some serious cell balancing issues.
@@thehhoff69 maybe you are right, I saw just 20r in green wrapped, and didn’t see 20s and specs of them)) few weeks ago I fixed dead Flexvolt 9ah, just replace 6 shorted 30t cells🤦🏻♂️
Hello from Ukraine!!!
What was the voltage of the entire pack before replacing the bad cell?
Wow that's lucky DeWalt pretty much told me to fock off, now I'm digging into Milwaukee no dead batteries yet!
I bought 4 Dewalt batteries and they died within two months from Lowes. I had to take them apart and recharge the individual cells. They store well if you re-charge them immediately.
That VTC5 is Sony /Muruta
yes if you put some flux on it before soldering
I’ve got two flexvolt 9ah batteries barely used at all and they won’t take charge or run any tools.
If they are under warranty yet (3 years) Dewalt should replace them no questions or recipes necessary!
@@radozeman it’s close they are staged 2021
Does anyone have service to fix two batteries like this one ? I have two flexvolt
Yes, I've got IR testers, spot welder, rebuilt 65 packs
Just bought a DeWALT kit that that has a bad 6Ah FlexVolt. I’ll be taking tires Approach on mine. 🙂✌️❤️
These flexvolt batteries are great but problematic. Most carpenters I know have got at least one bad flexvolt hanging around- including me. Dewalt give 12 months warrantee with no extension for registering them. I'm a carpenter and Joiner of 34 years experience.
I thought it was 2-3 years when I contacted them about my battery. They gave me a brand new one!
@@radozeman UK 12 month's
My dead ones had safety-tripped. No replacement needed, just reset the cell with a gentle pry under the top. My off-capacity packs were never good in the first place and a simple balance charge with a true 5S balance charger restored their capacity.
Ola vcs vendem ou consegue para mim apenas a carcaça Bateria dcb606-B3 ?? Esse mesmo modelo do video.
Can you use wire instead of the pan ribbon because my battery has corroded ribbons on one side and won’t charge
I would suggest getting more ribbon!
Use ribbon and spot weld but... If your ribbon is a lighter gauge than the original put another layer on. These tools draw a lot of amps and just like your house wiring it needs to be able to handle the current.
How did you know which one was bad???
Voltage test, bad cell had 0 volts.
Scuff, clean with electrical cleaner spray and use rosin type paste flux first, then add solder!
That’s what I’m missing is the flux.
@@radozeman the solder already has flux
I still add rosin flux
@@christophercarlberg6657 Depends on the age of solder. I repair electric issues on some parts, but wiring an entire vehicle (or less) I write the date or use masking tape. But when reheating an older soldered joint, the oxide formation increases the temp required to get some melting action. My SnapOn 400 watt works better, but not perfect as 400 Watt guns are expensive. I get a dab of flux on the solder melting starts. Solder in a zip-lock and liquid, paste rosin and acid new bags marked. Dielectric grease & tape in another. Most 50+ year old vehicles have had stories to tell, but you are right. If you got fresh rosin core last week, now fixing a broken trace, cold joint ands others every day, your rosin core is fresh. Have a good day.
DK, ASE Master Tech since 78, retired.
@@radozeman Even with a Power Point Presentation & 100 mechanics over 4 hours, I always forget something. Try GM advanced Charging Systems (5 types).
Enjoyed the video.
Get some Flux and brush it on the cell and it will clean the surface of the for you and make the solder flow better
Always use FLUX paste, even though the solder probably says it has flux in it. Then it would fuse to the contact with ease 👍
Dremel grindstone and some alcohol makes it easy even without flux. I just spot-weld
Will this work on the Dewalt 54v 6amp battery?
I don’t see why not
They are the same exact battery. Just marketing 60v in US.
I have own and operated battery businesses for 15 years and rebuild power tool packs for a living and I have never once seen a battery that a cell is paralleled with another cell ...In series parallel like the dewalt 60v and not have 2 or more batteries bad. That would be very very rare to see only the one battery cell out of the pair go bad unless one of the paralleled batteries was disconnected from the spot weld not holding. I have a feeling there was another bad or weak cell in that battery pack. Next it is a MUST YOU EQUALIZE THE CELLs in the pack to the same voltage with a b6 (or any other brand) equalizer/charger/discharging unit before charging on the origanal dewalt charger. Just some helpful info I hope.
That is a good point! I did get two new cells just in case, and I do have a balance charger that I use for my Li RC batteries.
Awesome. I like channels like your. You are trying to educate people and for free and I appreciate people like you bettering the world with help and knowledge
If ever need any power tool used or refurbished or not work for demonstration or whatever. I have everything power tools wise and thousands upon thousand of batteries that just need one rows replaced or any cell 18650 replacements cells for next to nothing In cost. Just throwing that out there. Keep up the good helpful clips. Thanks
@@pjbaldwin9643 do you have a website or offer rebuild services? looking for someone that rebuilds these batteries to send some i have for repair.
@@pjbaldwin9643 what brands of batteries?
You jump the 60v to a 20v. Use thicker wires to the 3 ways you choose b+ to b= and b- to b-. Say you use both b-. Plug in 1 wire to the b+ and these should be thin wires. It won’t spark as much but will heat up and spark a bit. Hold for about 5s or so. You might see the light turn on. Mine did but turned right off and showed completely dead battery but as soon as you put on the charger it will charge.
Did that to all my dead batteries, they don't last long, have to actually replace the battery
How do you figure that the bad cell?
No voltage on that cell.
@@radozeman But if they're connected with other cells, won't it show voltage of the other cells?
I hope your SODERING gets better, Unfortunately my soldering ( in Australia) isn't any better :( Cheers
Flux is what you needed. 👍
I don't solder them I spot weld them in with a small battery spot welder
yeah flux it dude...heating up the cells 3 times
Where I can find the screw driver?
I've got a whole set of them, most hardware stores will probably have them or online.
I'm interested in all bats for sale. I need a good price to buy it.
Hmm... I was at that moment just like you did on that battery.
I was curious why other people easily sticking tin solder when soldering, even with the cheapest solder.
lol... that's funny for me, till I know that a small dot of the flux (soldering paste) can make a huge effect.
Thanks for your video, I got some knowledge from that.
Always careful to bring more heat into battery cells. the solder-dot you saw on those cells and the thin plate was with spot welder.
Yes I know they use a spot welder, wasn’t going to buy one just for this, they are a bit pricey.
@@radozeman
No way, its about $10 bucks here, DIY made and good enough, I think you can make it too.
btw, your soldering station is awesome, want to have one too.. (but someday). I've still use the $3 solder.
by this video, seems like I will make my 6AH battery become 12AH.. hehehe
They are as cheap as $40!!! And can be found even cheaper at times!!!! Soldering at the cell should NEVER be done and this video should be deleted before some other idiot tries this and gets hurt, while destroying a battery.
If you're going to solder instead of spot welding, you should have bought a replacement cell that already had tabs on it.
i nwould of used a spot welder battery operated one 5000ah
Amazing how you can put terms into the search function and nothing worthwhile shows up until much later; this video popped up on my Premium feed. I have played all sorts of games trying to simply get the case off my DCB404, and it is driving me nutz. The black bottom section of the case refuses to separate from the battery cage. I see no more screws or locking tabs anywhere. I am hoping someone on here might have an idea, because I can't find anything anywhere. Thanx!
They do sale portable mini spotwelders
I have a Dewalt battery that doesn't hold charge for a long time.
I would like to replace some of the cells.
3.7v is the voltage of a good cell.
What is the level of voltage that means the cell should be replaced? some cells show 3.4v or 3.3v
You can find the 3.7-volt rechargeable battery from online store. (I've not sure if you mean exact output as you mention above for 3.3v or 3.4v).
Just check your battery cells code and it brings you the detail of the battery capacity, and by that code, you can find a similar battery cell.
try to find the branded battery cell for good quality, however, it will cost more than average standard battery cell out there.
I would charge it all the way up use it then check the cells, lower ones probably the culprit, though if they are all about the same, the whole pack is probably done.
I build battery packs all the time and when I first started off before I started spot welding them was I get a low temperature solder and a really hot soldering and iron and use tip tinner and put a little blob on the battery first then of tin the tab then a few seconds as soon as the solder liquified push down with wood stick until cooled then should be good solder
Ah ok good to know!!
I wonder if cooling the battery beforehand may help prevent damage to cells.
That is true, the charger actually won’t let charge if it is to hot!
Where did you get the battery? Do you have the link of where you got it? I would like to order 2 of these for the same reason and want to make sure to get the right battery.
From eBay, just search for 18650s
Go to any vape store. They sell them for Vape mods and kits. 18650.
The actual cells are
INR18650-20S
SAMSUNG SDI.
1163
I'd maybe recommend watching a few other clips first there are a few essentials you should know first that are not practiced in this vid. Just my opinion, best of luck
I NEVER go to E Bay to buy cells. Over the years I've got a few places that I trust. The 18650 Battery Store, Li ion Batteries, IMR Batteries and Sriko Batteries. Right now $5.99 ..😊
hello, I have a 54v battery and when I try to charge not light come in the charger and it doesn't charge but the charger works with others batteries what could be? chip inside the battery pack?
If it’s the same as what I had you probably have a bad cell! Check with DeWalt and see if it is under warranty yet!
Sir I need best flex volt battery charger
Its been more than a year now since your video, did the battery that you fixed lasted long?
Im having the same issue and im wondering it its worth to try to repair it. Thanks
No, it gave out a few months ago, not sure why I didn't take time look at it yet
@@radozeman ok thanks for the info
@@radozeman toss up whether that was because you didn't use the same cell as the rest of the battery (same peak current draw, same internal resistance, capacity etc.) or because of the soldering - some really cheap welding options these days for just a few $tens.
@Joser1948 this is an 18650 based flexvolt not the newer 21700 based flexvolt. He used the correct size cell but it wasn't matched to the brand/specs of the other cells.
Josef knew it was a 18650. He replaced a 2000mAh CDR 30A cell, Samsung 20S with a Sony VTC5 2600mAh and CDR of 20A. It had all the makings of a cluster f*ck
How about doing a review on those generic batteries I see ?
I do have a video on those! No 60v generic batteries though that I know of.
We watched a tutorial about how we shouldnt approach a battery repair.
lmao....You have to replace with the same C rating...they're 30C 2200mah.
You'll be lucky if only ONE 18650 goes out...
It was a nightmair...becuase other cells were bad too...they werent holding
charge ..after to recharge them...It took me a forever...so I was like fU$k it...
I had to break all the cells out.....recharge them indiviually ( I have multiple single cells chargers)..5 -ea were bad .lmao...even after I reset the diaphram.
You have to charge...and discharge a couple of times..to make sure
the cell are still good.
But --fu$k it....I had other bad packs that was given to me.
So i broke them all..I almost smashed all of it with a hammer....
i manage to rebuild 2-ea 24V ( 25.2) 6s.....
Used thick arss 300V rated wires...for the leads ( connector)..so i can recharge it on my R/C lithium chargers.....slapp them in POWERWHEELS.
Holy Fu4K....the soldering was a nightmair...becuase it wont sticks.
It took me forever ( i re enforced it with HOT GLUE to hopefully help
keep the solder joints in place....So far so good....but it took me
a good 5-6 hours worth of work p/pack...SLAVE Labor wages.
My grand kids are slave driver...lmao
I really want to try this. I have 3 dead 60v black and decker batteries....and like you said, they are about $130 each.
Alas, I have zero of the tools needed. Would you be willing to do it if I sent them to you?
All you need is a soldering iron, or better a spot welder.
@@radozeman what was the torx bit you used to open the case?
Next time you need to pre tin the cell and the tab. Then you’ll have an easier time.
Fortunately you won’t see it once the cover is on.
I was about to say something.. X )
One of mine went bad. I'm assuming it got wet from working in the rain. The charger rejected it at first and I figured it was too cold. After it warmed up the charger started charging it and 20 minutes later with lots of sparks and a smoking charger I unplugged it. Mail it in don't be like me.
They didn’t even want mine back, just sent me a new one.
Few problems....
1. The cell u pulled out was parallelled with another cell, 0v would appear in both cells. U should have replaced them both. That new cell will eventually discharge itself into the faulty cell and be faulty.
2. Sony vtc5 is 2600mah, the ones in the drill pack are 3000mah. Capacity mismatch.
3.U need to match the voltage of the new cell with the voltage of the cells in the existing pack to prevent over charge/discharge
The cells are wired in a series, not parallel, which I assume depending on the tool attached to is either in series with the other groups for 60v or paralleled to get 20v. The cells are 18650s so they should be an exact match.
My mistake, that is a flex vote pack...it is 5s3p when operating on 18v then when the switch is pressed it becomes 15s. The cells are samsung 2000mah at 30amp max. Matching capacity and voltage is still an important aspect for this application
@@radozeman Thanks for that, I was trying to figure how they got 60v AND 5ah from 15 cells when about 3.5ah is as good as it gets per cell.
The trick to those is a tab welder...
Right
How you got fire haha always use the same battery and check or all cells the same volts then spot welding it back xD
My partner has a lot of tools, so when he needed a circular saw, I ordered this one for him as a Christmas gift. ua-cam.com/users/postUgkxYDKeIjKLOfcwTgdin7TtCutsz4MbIc43 He is incredibly happy with the purchase. He stated that he likes that it is powerful, but still easy to use and cuts very well. He mentioned that it is important to know the right tools for the job at hand, and this compact saw has been exactly what he needed for a variety of projects at his rental properties and renovations. He also appreciates the battery packs, as stated, he owns a lot of DEWALT tools, so he is able to always keep batteries charged as needed.
Link to buy the cell
18650s on eBay
Where can I buy those cell .?
I have thousands of lightly used ones new ones as well. All come with warranties and are the high quality cells that are the same as Milwaukee or dewalt. We have pretty much every brand though to match you exact battery. It's best to go with lightly used so that you do not have the current cells In your battery pulling down the new more expensive cell when putting in series, replacing the bad cells. How many do you think you would need?
Tengo una flex volt que no carga como me puesde ayudar
amigo no vallas hacer lo como lo viste en el video ya aun soy inexperto pero se salto varios pasos importantes de seguridad
First of all how do you know which one is bad ?
Voltage test, bad one in this case was zero volts
18650:
18mm diameter
65mm length
0 no memory of charge.
Actually you can simply bypass that faulty battery. I think it’s still within the operating voltage with one cell left. Worth trying.
That is true it might have been.
if you bypass one of the cell battery, then one bank will be only around 14,4V of 18V or 50,4V of 54V.
hasn't tried yet whether the tools (18 V /20 V) will work on that voltage range.
20amp discharge new cell with 30amp discharge cells in the battery.
One way to save yourself some money! Pretty cool video!
It works!
Ogniwa muszą być zbalansowane układ sterujący nie naładuje pakietu.
TIP OF THE DAY: USE LOTS OF FLUX AND PRE-TIN BOTH SURFACES!!!!
Looks like you roughed up the battery surface which helps but flux really helps the solder stick to the battery tabs. This allows the flux to grip across both pieces and not create pigeon poop lol
I use the Kester self cleaning flux SP-30, and has made my soldering jobs look 100% professional.
I’ve read that SP-30 is not suited for electronics as it’s too corrosive.
@@IndianaJBird i'm half-way through my SP-30 lot and I haven't had any major issues.
@@hardkore360 yet tech specs says it's not, or at least must be careful: "Like other inorganic acid fluxes, Kester SP-30 is too corrosive for electrical or electronics soldering applications. In all cases, the flux residue should be removed after soldering to avoid any corrosion problem."
Wrong. You do NOT need lots of flux. Just a good idea how to solder is what's key here
use a 12 volt battery with 14 gauge solid wire and make a mini spot welder. no soldering on these please.
Ber en espanol
God, for $30 you can buy a DIY spot welder with the correct mosgets and capacitors. I've got $65 in mine and almost 5,000 welds.
OMG, I opened my DCB609 today and found the same battery cell was bad, but it's a 2018 battery, different with yours, cannot take the cell out.
Sad they made it complex to replace a cell.
If it’s 2018 DeWalt might replace it on warranty! That’s what they did with mine.
@@radozeman Yeah, the replacement is on the way.
Nice!
How do you know which cell is bad? 4 cells are usually connected together and it's hard to use the meter tested to find out which one is bad, so how do you do it? What am I missing.
@@NoNegotiations I do not really forget what I did to find that, use the multimeter to check.
Don't listen to me idiot's in the comments I don't even use solder I bend the tabs deeper and stick electrical tape behind the tabs and wedge it in the pack. You can hit the reset button under the positive battery post and could have reused the battery
Porque pones el título en español y toda la explicación es en inglés
continutinity I think man where curent goes to both parts
Continuity not connectivity
Missing critical information about how you diagnosed which cell was bad.
A volt meter! It was 0 volts.
RDAllen Thanks for the response. So you need to disassemble battery case and test each cell?
@@robertgressitt7879 That's what I asked, since usually 3-4 batteries are connected together, how do you diagnose?
There are other better method beside soldering. You should invest into getting a battery spot welder machine for safety. Soldering is a big NO NO...on any batteries..
Spot welder is definitely on the wish list!
Is that Ned flanders ???
Reality those are 18V with 54V
True!
They spot weld them to keep the heat lower but the spot welders are expensive.
Very true yes!
You can get a decent DIY spot welder for $15-$20.
dewalt not sending anything without their mechanic have broken tool or battery checked. they have 1 year warranty when you have to send your garbage in. i have many broken tools and customer service do not care. no compensation, just waste time and money to get working tool. every time you have to send garbage tool back to get new working one.
Hmm Sony batt sell you say !.....hmm thanks !
Sony 18650s.
Cool
The cringe factor watching this is right up there...
use flu solder flux
flu solder flux? that's a thing?
FLUX!
Maybe but it is self fluxing solder, plus the guide I watched this didn’t say to use any.
@@radozeman Oh ok since they are batteries it might be a safety measure, flux is a acid. For me that self fluxing solder still requires some flux to make everything flow and get a good solder joint, might be my horrible skills. Thanks for the video.
video edited down to 20 minutes, probably took an hour or more plus whatever the cell costs. my time is worth way too much to blow like this.
а на русском языке есть ролик . у меня на новом аккум. тоже одна банка не работает.
flux flux flux
sony vtc5 is the cell.
you are not professional you just damage things
flux anyone?
To much talking and don't go to the task and then repeat the same ,,, confused...
Jesus. That is way too much work.
you didnt explane how you find the problem thump down
I did in the first video, just a voltage check on each cell
Didn't repair bad cell.. you replaced
Replaced the bad cell, "repaired" the battery.
Jackhole
Replace is a repair. Thanks for video
You babble way soooooo much.