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Cleaning sealant off battery bus bars

Discussion in 'Generation 1 Prius Discussion' started by robert mencl, Jul 1, 2014.

  1. robert mencl

    robert mencl Member

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    Bus bars were corroded, and had lots of sealant on them, too.
    I soaked them in fingernail polish remover (acetone) for 5 minutes and the sealant turned to jelly and wiped right off.
    Then soaked in vinegar to clean to bare copper, then rinsed to remove acid.
     

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  2. JC91006

    JC91006 Senior Member

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    Great job! Most people take on stuff like that in the garage, you do it in the kitchen :)
     
  3. usnavystgc

    usnavystgc Die Hard DIYer and Ebike enthusiast.

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    Now what's for dinner? lol. :)
     
  4. chaps

    chaps Junior Member

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    Should have know this two weeks ago.Had to clean mine but used a very long process of soaking the corroded copper plates in coke over night then using scouring pad to bring back the shine.
     
  5. Jerry G.

    Jerry G. Junior Member

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    Now I should have seen this one sooner!! I spent 1/2 hour on the bench grinder wire wheel getting that stuff off fro just one side of the battery, then soaking in Lemon juice overnight. Well, they turned out nice and shiny. At least I can do this for the 2nd side!!?!!
     
  6. kutcht1

    kutcht1 Member

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    OK, I'll ask then. Why, was there a problem or did you just want to clean them and play with the HV battery?
    TomK
     
  7. Jerry G.

    Jerry G. Junior Member

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    Hi Tom,
    Being a journeyman low voltage electrician, when I see corrosion like this, it tells me that voltage transfer in and out of the cells could be drastically improved by removing the resistance between the connections and to prevent further damage to the bus. That's why I removed the battery. Also, to check the cells for any weaker ones that might be going out sooner than later. Preventative maintenance.
    Thanks for asking!!
     
  8. Jerry G.

    Jerry G. Junior Member

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    Oh yah sorry, I started a thread on my '02 "Prius not starting, P3125 code" error with a 345 sub code-Inverter problem. Figured what the heck, since the battery is such an integral part to the whole shebang, might as well check it out. Inverter is supposedly good as when I was replacing it, found the Mg1 motor connector wasnt bolted in place and the connector was loose. Whoever had this before me screwed it up-
     
  9. royfrontenac

    royfrontenac Member

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    Yes you are right, high resistance joints could cause local heating and voltage drop. After I cleaned my plates I silver plated them with a plating kit to allow an even better electrical contact. you found the problem in the inverter connection, as you have found out the codes do not give you an exact answer to the problem but lead you in a direction. Did the car
    The poor MG1 connections would have given unbalanced load currents in the stator during starting and maybe overheating of the connection. The unbalanced currents gave the 3125 code but the sub code was misleading indicating a replacement of the inverter when it was only a connection. Oh well another mystery solved. I am sure this will help others in the future. Glad you stayed with it, it was a tough problem.

    Roy from Canada
     
  10. robert mencl

    robert mencl Member

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    I'd like to get better at predictive diagnosis by charting under load the temperature of cells and of the connections listed above.
    If my car could talk maintenance would be easier and more accurate!
    Sadly, no Prius work this fall, working long hours at Peach Bottom atomic power plant, 12% power uprate project. It's a lot like a Prius, just bigger and cleaner.....
     
  11. Bobakanoosh

    Bobakanoosh Junior Member

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    I found a tip online that worked like magic. Literally, I was freaking out. My bus bar copper terminals were VERY corroded and tarnished. I popped them all out and put them in 3 cups of water, 1 cup of white vinegar, and 1 tbsp of table salt, boiled it for only about 10 minutes, gently shined them up with a brass brush (after rinsing and cooling them with tap water), and they look just like new. Seriously awesome I would highly recommend giving it a try.

    -Bob
     
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  12. DRACO

    DRACO Member

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    Oh Geez Brother Keith. much easier than the darn wire wheel on a drill thing I did. Wow we live and learn :)
     
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  13. Bobakanoosh

    Bobakanoosh Junior Member

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    I wasn't talking about the grime on the gen1 because that was covered nicely in this post already.

    If you have too keep it submerged for 2 hours the 10 minute boil and scrub is definitely a faster process. Plus most people will have vinegar, salt, and water in their house. Not many will already have that acid readily available in their house lol. Anyway it's cool to see the different ways to get those suckers clean!
     
  14. 2005pluginhybrid

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    I am interested in the reason for the water and salt?
    is it to make it safe to boil?
    Would straight vinegar not be better?
    I have tried soaking overnight in regular vinegar, washing with water and then light wipe with emery cloth.
    top - original
    middle - overnight soak in vinegar and wash in morning
    bottom - light cleaning with emery cloth
    IMG_20180209_112844692.jpg
     
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  15. Mendel Leisk

    Mendel Leisk Luddite

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    Just curious, which vancouver? In British Columbia, Canada, or Oregon, USA?

    Thanks for the photo and description!
     
  16. 2005pluginhybrid

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    British Columbia, actually Burnaby
     
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  17. Brian in Tucson

    Brian in Tucson Active Member

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    Vancouver is in Washington State, not Oregon.
     
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  18. 2005pluginhybrid

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    Yes it is in washington state, he was close though, just one river away. :)
     
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  19. Mendel Leisk

    Mendel Leisk Luddite

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    Like Kansas City, Missouri? (n)

    Had to ship a jump pack there once, had me confused.
     
  20. Mavi

    Mavi Active Member

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    I'm curious are you guys just cleaning the bus bars from the bottom or from both sides of the pack? I noticed the ones from the top of the battery back (towards the front side of car) have wires connected to them.. what do you do with those? Do they disassemble as well?
     
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