Lesson 1Battery repair process workflow: isolation, safe disassembly, cell verification, balancing, reassembly, and test cycleFollow safe step-by-step for battery repair. You go practice isolate, open packs, check welds and cover, change cells, balance again, seal back, and run test after repair before give back scooter.
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 into cell check techniques. You go measure inside resistance, guess capacity with time load test, find bad parallel groups, and decide which cells fit to keep or no good.
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 to get and read BMS data when e dey. You go check fault logs, cycle count, heat history, firmware version, and know when to reset or update or 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 make-up, common types, and how voltage, capacity, inside resistance work together. Learn how dem affect distance, power, oldness, and how to guess charge level for 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 to pick full pack change or cell fix. Compare money, safety, life span, work time, and risk so you fit tell rider options wey protect dem and your 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 problems to battery faults. You go check sudden stop, short distance, weak speed, bad gauge to know 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 interfacesSee how BMS protect pack and rider. You go study balance ways, over under voltage stop, current limit, heat sense, and how data go 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-touch tests before open pack. You go measure open voltage, check to spec, see rest voltage shift, and pick deep check or change now.
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 safe test battery on ride load and charge time. You go measure voltage drop, check charger out, charge take, and look connectors ports for 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 and clear talk with customer. You go explain heat run risk, store charge rules, carry safe, and write no-promise, waiver, warranty limits.
Recognizing and handling high-risk batteriesSafe charging, storage, and transport guidanceCustomer education scripts and checklistsDocumenting waivers and repair limitations
