Lesson 1Battery repair process workflow: isolation, safe disassembly, cell verification, balancing, reassembly, and test cycleFollow a proper, safe flow fi battery repair. Yuh wi do isolation, open packs, check welds an' insulation, change cells, balance again, seal up, an' run test cycles before gi' back scooters.
Isolation, PPE, and workbench preparationOpening packs without causing new damageCell replacement, welding, and insulationFinal balancing, sealing, and test ridesLesson 2Cell-level diagnostics: IR measurement, capacity estimation using simple timed load test, and spotting cell imbalancesGo deep inna cell-level tests. Yuh wi measure inside resistance, guess capacity wid timed load tests, spot uneven parallel groups, an' decide which cells fi save or too risky or costly.
Using ESR meters and four-wire techniquesTimed discharge tests for capacity estimatesFinding weak cells within parallel groupsCriteria for rejecting marginal cellsLesson 3BMS and firmware checks: extracting BMS logs/telemetry where possible, common BMS failure symptoms, and firmware reset/firmware update considerationsLearn how fi get an' read BMS data when yuh can. Yuh wi check fault logs, cycle counts, temp history, firmware versions, an' decide if reset or update safe or better change hardware.
Connecting to BMS apps, tools, or adaptersReading fault codes, flags, and event logsEvaluating cycle count and SOH indicatorsFirmware reset and update risk assessmentLesson 4Li-ion battery fundamentals: cell chemistry, nominal voltages, capacity (Ah), internal resistance, and state-of-charge estimationUnderstand Li-ion cell build, common chemistries, an' how voltage, capacity, an' inside resistance work together. Learn how dem affect range, power, agein', an' charge level guess in workshop.
Common scooter chemistries: NMC, LFP, NCANominal, max, and cutoff voltage per cellCapacity (Ah) vs. energy (Wh) vs. C-rateInternal resistance and its measurement basicsLesson 5When to replace pack vs. repair cells: economic, safety, and longevity criteria; pros and cons of cell replacement vs. full pack replacementLearn how fi pick full pack change or cell fix. Compare cost, safety, life span, work time, an' risk so yuh can suggest options we protect rider an' yuh business.
Cost comparison: parts, labor, and shop overheadRisk assessment: fire, recalls, and liabilityEstimating remaining useful life of old packsWhen to refuse repair and recommend new packLesson 6Interpreting symptoms: sudden shutdown at 40–50% and reduced range — common failure modes (capacity loss, increased internal resistance, BMS cutoff, cell group failure)Link real symptoms to battery faults. Yuh wi analyze sudden cut off, less range, weak speed up, an' funny gauge fi tell capacity loss, high resistance, BMS cut, or cell group fail.
Patterns of range loss and voltage sagSudden cutoff at mid SOC and BMS triggersDiagnosing weak cell groups in series stringsDifferentiating pack vs. controller issuesLesson 7Battery management system (BMS) role: balancing, over/under-voltage protection, current limiting, and telemetry interfacesCheck how BMS protect pack an' rider. Yuh wi study balancin' ways, over/under voltage cut, current limit, temp sense, an' how data show to controllers or check tools.
Passive vs. active cell balancing methodsOver/under-voltage and current protectionsTemperature sensing and thermal deratingBMS data lines: CAN, UART, and proprietaryLesson 8Preliminary non-invasive checks: open-circuit voltage, resting voltage distribution, and pack voltage vs. expected valuesDo quick, no-open tests before crack pack. Yuh wi measure open voltage, compare specs, check rest voltage drift, an' decide deep check or straight replace.
Measuring pack open-circuit voltage safelyComparing measured voltage to nameplate dataMonitoring resting voltage over several hoursRed flags that justify deeper investigationLesson 9Under-load and charging checks: voltage sag under load, charge acceptance, charger output verification, and charge port/connector inspectionLearn test battery safe while ride load an' charge. Yuh wi measure voltage drop, check charger out, charge take, an' inspect ports fi heat, rust, damage.
Simulating real-world load with test equipmentMeasuring and interpreting voltage sagVerifying charger voltage and current outputInspecting charge ports, pins, and wiringLesson 10Battery safety and customer communication: explaining thermal runaway risk, storage/charging guidance, safe transport, and warranty/legal disclaimersBuild safe habits an' clear talk wid customers. Yuh wi explain runaway heat risk, store/charge rules, carry safe, an' document waivers, limits on warranty.
Recognizing and handling high-risk batteriesSafe charging, storage, and transport guidanceCustomer education scripts and checklistsDocumenting waivers and repair limitations
