When a Bosch 14.4-Volt Drill That Wants a Charge

The Bosch battery pack that plugs into the handle on your 14.4-volt Bosch cordless drill has several battery cells mounted inside of it. If you plug your Bosch cordless drill into the recharger and the status light turns on, it indicates that the drill wants to take a charge. However, if the drill never actually charges, you can rebuild the battery pack with replacement battery cells and restore life to your worn out drill.

Locate the screws that secure the top half of the battery pack housing to the bottom half of the housing and remove them with a Phillips-head screwdriver.

Draw a diagram of the battery cells and how they position inside the housing. Each cell has a positive and negative wire connected to it. Label the wires and denote which cell the wires go to.

Lift the group of battery cells out of the housing and slide the wire terminals out of the battery cells by pulling on them with a pair of needle-nose pliers.

Slide the wire terminals into the slots on the replacement Makita battery cells, which you can purchase from many electronic component supply retailers.

Place the group of battery cells back into the housing and place the top onto the housing.

Secure the two pieces of the housing together with the original screws.

Place the Dewalt battery pack back into the Bosch drill and charge it as normal.

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How to Mix Old and New Batteries

Most manufacturers warn against mixing old and new batteries as well as batteries from different manufacturers. With most devices, mixing old and new Bosch 2 607 335 089 batteries will simply drain the new battery faster, costing you more money than if you had bought new ones. However, mixing batteries in some older devices can lead to battery leakage or explosion. For instance, if the device does not have a low-voltage detector to prevent the device from trying to draw energy from a dead battery, the battery may be over-discharged and could potentially explode. Mixing batteries also forces the new batteries to work harder, which can cause them to overheat. That being said, sometimes you only have a few new batteries, but not enough to replace all them in a small electronic device. As long as the device is small, mixing batteries can be completed successfully and safely.

Make sure the device that needs the Bosch 2 607 335 533 batteries is fairly new and small. The risks associated with mixing batteries are minimized in smaller devices. For example, mixing old and new batteries in a television remote will provide you with plenty of battery life.

Stick to the same brand. Using the same brand of batteries will prevent any problems that may arise from mixing different kinds of batteries, such as serious overheating.

Replace as many of the old batteries as possible. A device must have a certain amount of power, or voltage, to work. Since the old batteries will not be providing their share, the new batteries are forced to work harder to provide the power, running them down faster. Using as many new batteries as possible eases the strain on the new batteries.

Keep track of which device has mixed batteries. Doing so will help you remember to exchange all the batteries the next time, instead of having to continually mix batteries, which is not good for the device and will cost you more money.

Replace all the batteries as soon as possible. A full set of fully charged batteries will ensure the maximum life for both the Bosch 2 607 335 685 batteries and your device. This means throwing out all the batteries, as the new ones have been draining faster.

Do not try this in old or large devices. This will increase the likelihood of serious and dangerous malfunctions.

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How to Jolt a Nicad Battery Back to Life

You have purchased expensive reusable nickel-cadmium Bosch 2 607 335 536  batteries in the hopes of saving money in the long run. Instead, you are met with frustration because the batteries no longer hold charge. Fortunately, there is a solution known as jolting, or zapping, using common items found in the garage. If not exercised regularly, nickel-based rechargeables develop an inner crystalline formation, which degrades the charge quality. Jolt your nicads using a 12-volt DC power source to break up crystallization, thus saving you money.

Wear all proper safety equipment. Set your volt-meter to the proper range for your battery. Hold the red lead on the positive battery terminal, and the black lead to the negative terminal. Read the meter: If the tested voltage is under 90 percent of the voltage labeled on the Bosch BAT040 battery, then it needs to be jolted.

Separate the alligator clips from the 12-volt battery charger so they are not touching anything conductive. Turn on the battery charger. Hold the red/positive clip to the positive terminal of the worn battery. Tap the black/negative clip against the negative battery terminal 10 times, taking care not to hold a connection. Repeat this process for each worn nicad battery you have.

Test each battery again: if the reading is still below 90 percent, repeat the jolting process until a desired reading is achieved. Shut off the battery charger. Recharge the refurbished batteries in their respective chargers for the factory recommended amount of time.
Fully discharge and recharge your nicad batteries every few uses to avoid the need for future jolting.

Only jolt nickel-cadmium (Ni-Cd) batteries, as other battery types may explode.

Do not HOLD the alligator clips on the Bosch BAT412 battery, as they may overheat or leak.

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How to Condition NiMH Bosch Batteries

Nickel Metal Hydride (NiMH) Bosch D-70771 batteries are commonly used to replace AA and AAA alkaline batteries. NiMH holds an advantage over traditional alkaline technology in that NiMH can be recharged. This can add up to a substantial savings over the life of your battery operated device. To get the longest life and best performance out of your NiMH batteries, they must be used correctly.

Charge the battery completely before using. The first charge should be a complete and slow charge. Do not use quick chargers to perform this initial charging.

Use the battery until it is drained. After the initial charge, use the battery until it is drained and then recharge it. The second charge can be done using either a regular or quick charge device. Although, they charge the batteries in less time, your batteries will discharge faster if you use a quick charger.

Recharge the battery whenever power gets low. NiMH batteries do not need to be completely discharged each cycle. You can connect the batteries to the charger whenever the power starts to get low.

Cycle the Bosch 2 607 336 092 batteries to obtain maximum life. Approximately once every 30-60 days completely discharge the batteries by letting the device that they are powering run until shutdown. Allow the NiMH batteries to remain in a discharged state for four to six hours. Then recharge the batteries using a non-quick charge method and resume normal use.
NiMH batteries are superior to the older NiCAD batteries in that NiMH does not have to be completely discharged with each use. Typically NiMH batteries are available in AA and AAA sizes, however some specialty electronics stores carry C and D NiMH cells.

Never dispose of batteries in a fire. Take your used batteries to a Bosch 2 607 335 278 battery recycling station for disposal. Contact your local government offices for details.

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Rechargeable Battery Care and Maintenance Guide

There are basically three types of rechargeable Panasonic power tool batteries available for use with consumer electronic products: nickel cadmium (Ni-Cad), Nickel-Metal Hydride (NiMH) and Lithium Ion (Li-Ion). I will discuss the advantages, disadvantages and ways to improve battery performance for each of these three types of rechargeable batteries.

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NI-CAD Batteries
Ni-Cad batteries are probably the most commonly known type of rechargeable batteries in use today. These batteries have a good capacity and maintain a stable voltage throughout their discharge cycle. The stable discharge voltage allows electronic devices, using Ni-Cad batteries, to operate throughout almost the entire discharge cycle. Another advantage to Ni-Cad batteries is that they have a reasonable shelf life between charges. The main drawback to Ni-Cad batteries is the “memory” effect. Another factor that plagues Ni-Cad batteries is the limited number of recharge cycles before the batteries must be replaced. Ni-Cad batteries will usually require replacement every 1-2 years.

Ni-Cad battery memory effect is generally described as the battery operating for a shorter and shorter period of time as the battery gets older. The reason for this is that most people user their Ni-Cad battery operated devices and then promptly place the device into the charger. Over time Ni-Cad batteries develop crystals in the unused portions of the battery material which prohibit the chemical reaction that produces electricity. If you only use your Ni-Cad battery for 30 minutes before placing it back on the charger, over time, your battery will only be able to operate for a maximum of 30 minutes (hence the term memory effect).

There are two simple steps that you can do minimize Ni-Cad battery memory effect. First, always use your Ni-Cad battery operated device until the battery is completely drained. This will minimize crystal build-up and extend your battery’s useful life. Another way to increase your Ni-Cad battery’s useful life is by performing a deep discharge cycle about once a month. A deep discharge cycle is achieved by operating your Ni-Cad powered device until the device completely stops operating. Performing these simple steps should ensure that you achieve maximum life out of your Ni-Cad Hitachi power tool battery.

Ni-MH Batteries
Ni-MH batteries are a newer technology of rechargeable batteries. They have the same advantages as Ni-Cad batteries but they don’t suffer from the memory effect. They also have a longer useful life cycle; about 3-4 years before requiring replacement. The main drawback to Ni-MH batteries is that they have a fairly high discharge rate while in storage. For instance, if you fully charge a Ni-MH battery and then leave it unattended for about a week, it will lose about 20% of its charge.

To avoid this problem, it is advisable to keep your Ni-MH batteries in the charger when they aren’t in use. Because they don’t suffer from the memory effect, keeping them on the charger won’t do any harm. NiMH batteries are more expensive than Ni-Cad batteries, but they will last a lot longer. In the long run NiMH batteries turn out to provide better value.

Li-Ion Batteries
The newest category of commercially available rechargeable batteries are the Li-Ion power tool batteries for AEG. These batteries have all the advantages of Ni-Cad and NiMH batteries plus they have a longer useful life than either of these two types of rechargeable batteries. The main disadvantage to Li-Ion batteries is that they lose about 10% of their useable capacity each year due to chemical breakdown within the cells. There is nothing that can be done to prevent this condition..

Li-Ion batteries have a typical useful life of between 300-500 discharge cycles or about 4-5 years. You can maximize the useful life of your Li-Ion batteries by keeping them on the charger during use (e.g. laptop computer) or keeping them on the charger when not in use. Because Li-Ion batteries are “smart” batteries they cannot be overcharged.

Because Li-Ion battery life is dependent on the number of discharge cycles, anything you can do to minimize the number of discharge cycles will, in effect, increase the battery’s useful life.

Here’s a Li-Ion battery maintenance tip; Li-Ion batteries should be conditioned about once a month. Most Li-Ion batteries have a fuel gauge on the battery (i.e. the LEDs on one side of the battery with a test button) and the electronic device (usually a laptop computer) also has monitoring software to manage the battery power. The accuracy of a Li-Ion battery’s self-monitoring circuitry degrades after about a month of use. If you notice that your battery’s fuel gauge or your device’s operating time estimate is way off, then you probably need to condition your battery.

To calibrate (or condition) your Li-Ion battery, fully charge your batteries (let them charge overnight even if they appear to have a full charge) then operate your device until it shuts down. Recharge your batteries and you should notice an improvement in the accuracy of the operating time prediction.

Here’s a Summary of What You Need to Know About Rechargeable Batteries

Ni-Cad Battery

PRO: Steady Voltage Throughout Discharge Cycle, Good Shelf Life
CON: Suffer from “Memory Effect”
TIP: To minimize memory effect, always operate your Ni-Cad batteries until fully depleted. Completely discharge Ni-Cad batteries about once-a-month
NiMH Battery

PRO: Steady Voltage Throughout Discharge Cycle, no “Memory Effect”
CON: Shelf Discharge Rate Higher Than Ni-Cad Batteries
TIP: Keep NiMH batteries on charger when not in use.
Li-Ion Battery

PRO: Steady Voltage Throughout Discharge Cycle, No Memory Effect, Better Shelf Life Than NiMH Batteries
CON: Lose About 10% Useful Capacity Each Year
TIP: Minimize battery cycles by keeping Li-Ion battery operated devices on charger when available. Condition Li-Ion batteries about once-a-month to keep them calibrated.
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What Batteries Will Fit 18V Ryobi Tools

In a world of RYOBI power tool batteries, battery packs and chargers with endless combinations of connectors and sizes, Ryobi Tools keeps it simple. All of the company’s 18-volt tools, sold under the “One+” product line, accept the same batteries, regardless of the type of tool or the date of purchase. Tools brought home from the store yesterday use the same 18-volt battery packs as 10-year-old tools. Ryobi offers three varieties of 18-volt battery packs for its tools.

Ryobi’s One+ line of tools includes more than 40 tools that are powered by 18-volt battery packs. Tools include standard power tools such as drills, saws, sanders and trimmers. However, other devices utilize the One+ 18-volt battery, including vacuums, flashlights, radios and portable fans. The 18-volt batteries for new devices are compatible with old batteries, and new batteries are compatible with old devices.

Nickel cadmium batteries for power tools are the value side of Ryobi’s 18-volt batteries. They’re heavier, bulkier and don’t provide the punch that the lithium ion batteries do. However, you could buy two batteries and keep one on the charger for less than one high-performance lithium ion battery.

For jobs that don’t give much space for tools, the compact lithium ion battery is ideal. It’s also useful for work done above the head. Weighing in at about a pound, it’s 45 percent lighter than the nickel cadmium option. Ryobi claims that it performs 20 percent better than the nickel cadmium battery pack and holds its charge four times longer. At the time of publication, one compact lithium ion battery cost about $10 less than a two-pack of nickel cadmium batteries but about $40 less than the extended-life lithium ion AEG cordless drill battery.

The high capacity battery pack holds the longest charge of all Ryobi batteries. Despite being larger than the compact lithium ion battery, the high capacity battery weighs 1.6 lbs. — less than the 1.9-lb nickel cadmium battery pack. It features a fuel gauge, allowing you to monitor power remaining before the battery pack dies. This additional feature and the higher charge capacity come at a price, though — $89 each at the time of publication.

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How to Reset DeWalt Power Tool Batteries

DeWalt has a selection of woodworking tools and power tools that contain a rechargeable nickel-cadmium battery pack so you don’t have to deal with electrical extension cords and trying to locate a electrical outlet. DeWalt DE9036 battery packs are quick to charge and long-lasting, and contain a microchip that shuts the battery pack off if it overheats. Once the battery pack shuts off, you have to reset it. The reset process clears the microchip’s memory and gives the chip the “all clear” to charge normally.
Press the battery pack removal button, located on the back of the power tool’s handle, to release the battery pack from the DeWalt DE903 power tool battery.

Slide the battery pack along the rail track, on the bottom of the power tool, to remove the pack.

Place the battery pack into the battery pack charger with the metal contact side matching the metal contacts in the charger.

Let the battery pack charge for eight hours. Your DeWalt DE9038 battery pack is now reset.

Reset/charge the battery pack at room temperature (at least 68 degrees Fahrenheit)—do not place the battery charger in a cold garage or other area that is below room temperature. This could lead to the charger failing and the battery pack not resetting/charging.

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NiMH Drill Battery Charger Instructions

NiMH batteries can be recharged and used multiple times. These Dewalt power tool batteries are easy to charge at home with an NiMH battery charger. Learning to use the charger is simple and can be done in just a few minutes.

Choosing an NiMH Battery Charger

There are quite a few options available when choosing a NiMH battery charger. Consider how many batteries the charger can charge at one time. Some can charge up to 10 AA or AAA batteries at a time, while other chargers can only charge two AA or AAA batteries at a time. How long the charger takes to fully charge batteries is another consideration. Some supposed “quick chargers” can actually take up to six hours to fully charge batteries, while other models can fully charge your batteries in 90 minutes.

Understanding the Manufacturer’s Instructions

Be sure you understand the manufacturer’s instructions before charging your NiMH batteries. The risk of serious danger is low, but there is a possibility that your Makita power tool battery charger could overheat if it is not used properly.

Using the NiMH Battery Charger

To use your NiMH battery charger, begin by plugging it into an ordinary wall outlet. If your charger is equipped with multiple charging settings, select the setting and insert the NiMH batteries into the charger, being sure to observe the correct polarity of the batteries. When the light on your NiMH battery charger changes from red to green, your batteries for Bosch power tool are fully charged and ready for use.

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How to Charge Tool Batteries Hooked in Series

Recharging a single battery is straightforward; connect it to a commercially produced battery charger designed for that type of battery. When several batteries are linked in series, their voltages are combined, so three separate 12-volt batteries become one 36-volt battery. This situation is common in solar power arrays, and in trailers with more than one 12-volt vehicle battery. Charging linked batteries is possible in several ways. An understanding of the rules of electricity allows you to select a method suited to your needs and resources.

Choosing a Charging Method

Step 1

Decide how to charge the Hitachi power tool batteries. The number of batteries and battery chargers that you own, the voltage ratings of your chargers and time available for the recharging will influence your choices. Select the method that suits your circumstances.

Step 2

Charge any number of batteries with a single battery charger if that is the only charger you own. This is a slow method and you will need to disconnect each battery from the series before charging it.

Step 3

Charge all the batteries contemporaneously with multiple chargers if you own as many battery chargers as you have batteries. This is faster than charging the batteries one at a time, but requires plenty of battery chargers.

Step 4

Charge the entire battery chain with only one battery charger if you have a high voltage charger. For example, charge two 12-volt car batteries together using a 24-volt charger.
Charging Each Battery Seperately

Step 1

Disassemble the series Panasonic power tool battery. Disconnect the battery links and move the individual batteries apart to ensure they have no electrical contact with each other.

Step 2

Charge each battery, one at a time, by connecting a charger across the terminals. When the first battery is charged, move to the next until every battery is charged. Use a charger rated for the same voltage as the battery.

Step 3

When all the batteries are charged, clean the terminals, and reconnect them to form a series battery. Ensure that the connections are tight before using the battery.
Charging Multiple Batteries with Multiple Chargers

Step 1

Attach a battery charger to each battery, but do not switch it on. With all the batteries connected to chargers, switch on the chargers to start the recharging process. For example, to charge a series of five 12-volt batteries, use five 12-volt battery chargers, one connected to each battery

Step 2

Monitor the charging. Some batteries may recharge before others. Signs of gas escaping from batteries, or the cases becoming hot, indicate that a battery is overcharged. Stop charging immediately.

Step 3

Switch off the chargers and remove them from the batteries. The serial battery should now hold a full charge.
Charging with One Higher Voltage Charger.

Step 1

Ensure that all the battery connections are tight and the terminals are clean. Double check the number of batteries and the total voltage.

Step 2

Connect the charger across the end positive and negative terminals of the series. For example, with a series of five batteries, connect it across the free terminal of the first battery and the free terminal of the fifth battery.

Step 3

Monitor the charging process to detect AEG tool batteries emitting gas or feeling excessively hot. Stop charging if any batteries exhibit these signs; clean and tighten the terminals and try again.

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How to Improve Your Cordless Drill Battery

I hate it when my cordless drill gives up in the middle of a job. It seems that the supplied battery packs just don’t cut it. So I opened up the battery pack and replaced the Ni-Cad with much longer lasting Ni-MH batteries. Now I get a much longer use between charges.

My Panasonic drill battery pack had 4 Torx screws (I later replaced with regular Phillips screws for easier access). Inside you’ll find 10 NiCad batteries. They appear to be just a bit smaller than ‘C’ cells, and all attached together in series. 1.2 volts X 10 cells = 12 volts. The cells are marked as 1300 mAH which is why they don’t last very long. You will probably want to photograph the arrangement of batteries since you will need to make a new pack look just like this. Also notice the thin insulator that keeps the top battery from shorting against the batteries on the bottom.

Aquire a new set of identically sized batteries. In my case the size is called ‘Sub-C’. I got them at BatterySpace.com for $24.00. They come with tabs attached. Carefully assemble the new cells into the same arrangement as the original, and solder the tabs appropriately. Be careful not to short out a cell while assembling it – even briefly! You will also need to scratch the surface of the leads before soldering and put a thin coat of solder on each tab before assembly (called tinning). Re-assemble and test. Be sure to re-use the fusable link that came with the original battery pack.

Capacity:The new batteries are rated at 3000 mAH, so expect more than twice the run time than the original pack. You may wonder — will the higher capacity hurt the tool? No: the important thing here is that the voltage is the same, but you may end up working the tool harder with the increased capacity, so don’t over-do it. I’ve been using it for about a year and a half, and it’s been excellent.

Charging: Since my old charger is expecting to charge 1300MAH NiCads, it will require a much longer charging time. The spec sheet that comes with your new batteries should help you here. Also checkout batteryuniversity.com for more important detailed info on charging different types of batteries. A better charging method may increase your Hitachi cordless drill battery life.

Why do the batter packs die? I’ve been analyzing the old cells, and I’ve noticed that several of the cells are bad, but many of them are ok – it only takes one dud to render a battery pack useless.
Since the drill came with two battery packs, I can combine the good ones to make a second working pack. The old cells can be tested as shown below – the important part here is the load. I’ve used a flashlight bulb as a load which also server as a visual indicator of the battery’s charge. Testing without the load will give useless results. I’ve seen some cells read 1.2volts without a load — which seems good, but drop to 0.3 volts when the load is added — clearly a dud.

Economics: A good mod should be economical too! Sears wants $40.00 for a new battery pack – if you can find it (I paid about $75 for the tool with two batteries – so why is a replacement so expensive?) So with this mod, I get a better Ryobi power tool battery for $24.00

Safety notes: Like many of the projects here on instructables, there are potential safety problems if you don’t know what you are doing — so if you don’t know your series circuits from your parallel circuits STOP! don’t attempt to perform this mod – it can be potentially dangerous if the cells are mis-wired or short circuited. Also beware any leaking chemicals from bad cells. Also make sure your soldering skills are sufficient before working on this project. A reader from Makezine’s blog noted that one of the solder tabs is thinner than the others – this acts as a fuse – make sure you include the fuse in your completed pack.

Environmental issues: dispose used Ni-Cad cells properly. Your new Hi-Mh batteries are more environmentally friendly though some still recommend re-cycling.

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