Hello PC members A friend of mine has asked for help repairing his hybrid battery which has a high voltage leak and I'm having some trouble diagnosing the issue. I'll first state that the leak is definitely within the battery as he replaced the hybrid battery with another unit and the car has been fully functional since (7 months and 23k miles) The battery is out of the car now but I can put it in the car if I absolutely have to, I also do not have an isolation tester. Any input is greatly appreciated. Posted via the PriusChat mobile app.
Try to not kill yourself. This is not a project to undertake without a thorough understanding of the battery. You need to be very clear about that a high voltage leak means the battery case is a live part of the circuit. This reading was taken from a leaking Gen 1 battery. The battery will have high voltage present until all the bus bars are removed from one side. Once all the bus bars are removed leaks can be often be found with just a voltmeter. Measure between the case and every module terminal. Leaks can be intermittent. If the battery has sat for months the leaked electrolyte can dry up and break the voltage path. Be very careful.
Yeah, wholeheartedly agree try not to kill yourself!!!!! But here's how you should be able to narrow down the trouble, #1 gloves, multimeter #2 one probe on the 1st busbar the other to the case. Check busbars on one side against the case as the voltage 1st should go down then starting to go back up if you read 0 V or only 7.2V on only one bus bar against the case that's where the leak is. If it's 0V it's on the terminal facing this side if it's 7.2 it's on the opposite side My $.02 terramir PS: of course if you have no voltage between the case and the bussbars as mentioned the path may have dried up but then there is only one recourse charge the darn modules non to gently to get this going again. Remember to cool with lower duct and blower on a good 12 v PSU.and stuff a rag in there with the blower to seal the aurpath a bit. Wear safety goggles since at least one module is leaking and you dun want that crap in your eyes a mask might be good too a decent painters respirator will do.
