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How to replace cells in a rechargeable 18V DeWALT DE9095 2.0 drill

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My old drill - About to get a new lease of life!

replacebatterycells

New Cells available from:

You will need

  • New cells, with tabs, available from the link to the right: small battery company: Tel: 020 8871 3730 (link at the end)

    I bought sub C 2400mAh 1.2 NiCd Tagged Battery 15 pack for 12V (Cost £36.00 in January 2013)
  • A good soldering iron
  • Electronic solder with a flux core
  • Assorted screwdrivers and torx bits
  • Cardboard (Optional)

How to remove old batteries

  • Remove the torx screws from the battery pack, remove the lid and lever the batteries out with a couple of flat bladed screwdrivers.

Empty battery case

Empty battery pack

Empty battery pack

  • Keep the battery pack intact so you can copy the connections (!) - this is very important for later on.
  • I found that it helped to number the old batteries and new ones with a permanent marker.

Old battery pack

Old batteries numbered

Old batteries numbered

Make a drawing of your connections and make sure you have a proper circuit eg. positive to negative all the way round.

Diagrams of connections

Diagram 1 - My circuit diagram

Diagram 1 - My circuit diagram

Diagram 2 - Bottom view diagram

Diagram 2 - Bottom view diagram

Diagram 3 - Top view diagram

Diagram 3 - Top view diagram

How to replace cells

  • Arrange your new, numbered batteries leaving the heat shrink on the tabs!!
  • I found it easier to put the new numbered batteries in the battery casing, as this kept them in the correct shape and position and made it easier to solder.
  • Start soldering all the batteries together in the correct order. Diagram 2 (Only removing heat shrink when you’re ready to solder!)
  • Turn over and solder the connections on the other side. Diagram 3
  • You may need to trim some tabs as some are too long.
  • Tape can then be wrapped round the batteries to hold them together.
  • The positive of battery 8 connects to positive post of the plastic insert that goes into the drill handle.
  • The positive of battery 15 will connect to negative of battery 10. Diagram 1
Photo 1 New batteries - numbered and soldered

Photo 1 New batteries - numbered and soldered

Photo 2 Battery number 8 - positive

Photo 2 Battery number 8 - positive

Photo 3 Battery number 10 - negative

Photo 3 Battery number 10 - negative

  • Put cardboard back on, with pritt stick, to provide a cushion between the batteries and the case. (I made a new one as mine was broken.)
Photo 4 Cardboard cut out

Photo 4 Cardboard cut out

  • Insert the positive tab of battery 15 into the holder and solder the tab onto the negative of battery 10. Photo 6
  • This sits on top of battery 9

Battery 15

Photo 5

Photo 5

Photo 6

Photo 6

Photo 7 Solder the lugs

Photo 7 Solder the lugs

  • On the other end of battery 15 you need to solder a wire onto the positive post of the plastic insert that sits on top of the battery. Photo 8
  • The other end of the wire will be soldered onto the positive tab of battery 8. Photo 9 and diagram 1
Photo 8

Photo 8

Photo 9

Photo 9

  • Replace the battery lid and screw shut.
  • Put your new battery on charge and celebrate that you have reconditioned your drill for less than half the cost of a new battery pack!

Finished job - You have saved a fortune!!!!

Charging perfectly!

Charging perfectly!

replacebatterycells

Small Battery Company

Comments

jaime on November 05, 2013:

gj p