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

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

New Cells available from:

• Small Battery Company - Watch, photo, hearing aid and other small batteries for sale on-line.
  Watch, photo, hearing aid and other small batteries for sale on-line. Free delivery in UK. A bargain camera, button cell or lithium battery. Credit and Debit cards accepted.

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

• 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

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

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

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• 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.)

• 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

• 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

• 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!!!!

Small Battery Company

• Small Battery Company - Watch, photo, hearing aid and other small batteries for sale on-line.
  Watch, photo, hearing aid and other small batteries for sale on-line. Free delivery in UK. A bargain camera, button cell or lithium battery. Credit and Debit cards accepted.

Comments

jaime on November 05, 2013:

gj p