First hybrid rebuild questions Gen2

For me, this is how I do my stuff. I don't think there are specific laid down procedures.

1. Test all open voltages on the modules, and anyone low, I'd replace them with a good one with nice capacity.

2. Discharge/charger the replaced modules along side the pack.

I don't normally disassembly the modules from the pack while discharging/charging.

That helps to compress the modules to prevent overheating, for instance, if my charger was set at 7.0A.

3. Observe the pack for some days, and remove the weak ones.

4. Exercise the pack again for some days, then finally assembly.

5. I don't have tour kind of charger, but I have made a custom charger for my use.

Charging voltage output are, 10, 30, 100V with 3.0A charging current.

I have a fan placed close by blowing across the pack for cooling.

6. Get a tech screen to help you view the live stream of the hybrid system, as you test drive the car, when you partially assembly the pack in the car.

Ensure you erase all codes, then go for a long test drive. I usually do, 300mi.

7. How much did you get your charger for pls?

Dxta

 

1. Discharge safely to 6.0V

2. Yeah, you can test the modules further by load testing with a headlamp bulb. That's how I do them.

3. Bad modules would loose within any amount of time, as compared to the healthy ones.
Load testing them, makes the weak ones surface almost immediately.

4. I wished it were possible to buy those chargers in Lagos, Nigeria. Its a pain getting them here.

5. I'd PM you to look at the possibilities of getting the charger to Lagos.

 

1. Acceptable limits, would be 8.0V, and maybe ideal would be 7.2V I think.

2. The charger(s) would be what I'd want in the mean time.

If you want us to discuss, or I give you a call, that would be OK with me pls.


PS: I fix lots of prii, camries, highlanders, and some few ford fusion vehicles too.

 

For volume like that, you definitely need something less laborious. Have you investigated the Prolong charger? A lot of us use them on our own Gen 3 and Gen 3 Prii.

 

Since the charger and alligator costs $107, I'd need three of those. That would be $107X4=$428.

 

I did a quick look through the attached, and did not find that info, but a lot of info nevertheless.

 

Personally used it both ways, with a harness installed in the vehicle and again using it to fully charge/balance another battery pack out of a vehicle (bought another harness for that project).

There are two (2) entry level consumer devices being sold (and other professional grade products if you must):

1. The charger doesn't have an auto shutoff feature, which shouldn't be a deterrent.
2. The intelligent discharger (with auto shutoff) is spot on, and works as advertised.

 

I see that @SFO beat me to it and answered it well.

A full recondition takes three days or more with the battery installed, but very little of your time. That's once you've done the one-time harness installation. What's nice about charging it in place in the car is that the charger runs the battery fan full speed the whole time to keep the battery cool. Or, if the battery is out for rebuilding, you can charge it on the bench, but will need to keep it cool.

It's a HUGE labor saver compared to having to access individual modules with hobby chargers.