Faulty Bosch 18V ProCore Battery - Issues, Diagnose & Repair

Bosch ProCore battery has clever design, but it still fails. In this video I investigate the problem and fix it on the budget. If you want do something similar - here some used parts down below.

Use parts:

[benxx]

Followed your video. 4 cells around 3, 8V. 1 was at 0, 4V. Swapped the faulty one with a reclaimed 40T @3.35Euros. Used a cheap spotwelder with strips of nickel et voila. All leds green and the charger said "Thank you". Great video, really works for me.

[aliancemd]

I love that they use 0.3mm copper, all the other manufacturers slap the cheapest and easiest to solder strips that they can find(nickel-platted steel) and call it a day.

[tryagain]

I enjoyed how thorough and correct this video was. It would be interesting to see an alternative version of this video for people who only have basic tools - voltmeter, hacksaw, soldering iron.

[vernehenzel]

Some of the Bosch battery housings (like the one I bought in 2021, which failed in 2024) are put together with screws like in this video. I had trouble taking it apart until I realized that one of the screws is covered with a plastic plug. Just dig into the hole with a screwdriver until you make contact with the screw head and it will come out like all the others.

[TranTek]

the samsung 40T has major issue failure version 1 and 2

so far version 3 needed to wait and see
great video
Kwelder is releasing a copper welder version

[jcvjcvjcvjcv]

You can pull the tabs off without the ball grinder. But your way they come off flatter which is a nice bonus.

2:40
Heat the red housing and it will more easily let go of the cells. Same before re-inserting cells. Better not rotate the cells when inserting or you might damage the balance contacts.

4:33
I have the same spot welder and I can weld those copper tabs just fine.

6:00
Wow, that is a nice charger.

Aren't you afraid the new cells combined with the older cells remaining in the pack will soon give issues? I tend to replace all at once. The Bosch battery itself doesn't do balancing, only monitoring.

[MCsCreations]

Fantastic tips, dude! Thanks! 😊
I have a ToolKitRC M6 and it's great!
Happy new year! And stay safe there with your family! 🖖😊

[chriscole]

Great video. Thanks for the useful info on the Bosch battery packs.

[ZTeam]

So by the time we get all the tools and parts, it's cheaper just to buy a new battery. Thanks!!!!

[Arek_R.]

LI-ON battery pack factories building packs for example of 40 cells will discard entire assembly if there's one bad weld.
Those are being then handed over to recycling company.
Someone at the recycling company takes them and then disassembles those for sale instead of recycling those.
Much greener than just grinding those unused cells to raw materials.

[djmulder]

the balancing interests me. Like all poles were connected, how does it supply charge to an individual cell? wouldn't all current just spread out over all poles?

[hericar]

I really like how you explain all the process! But, how can i balance the cells without a fancy charger like this?

[ijjyahmed]

Very good video. Everything done very well.

[nehemz]

you can still reuse that copper strips afaik if you can weld it

[donalexey]

I didn't have a charger with BMC, so I balanced the cell with a 12V car lamp. It was painly boring, but I managed to succeed.

[benxx]

Where do you solder the orange, white and black wire?

[taaviplaan]

you left 3 old cells and installed 2 new cells / you think they have same capacity? Soon the battery will get out of balance and then you will need to balance again.
Next time replace all cells

[dusanmilojevic]

You can do that on older batteries not on newer.On newer electronic board will lock when cell are dead or disconnected from cells.

[ВилиамРит]

Cool!!! Bravo!!! Good tip. /// Хороший совет! Отличный ремонт!

[ealneas]

Can someone recommend a replacement bms board for those batteries? I have the older lithium batteries