powerdrive 17935 charger issues

gilbertj77080 · 03-16-2016, 07:39 PM

i have a powerdrive on board charger 17935. it don't turn on and charge is the issue. i'm running a 4 12vdc battery set up. the batteries are 46.5vdc, plug in the charger and nothing. if i jump the wires on the black relay then it charges. i was told two theories, 1 is the relay is bad and the other is that the electronic timer board is bad. any thoughts? thanks in advance

Sergio · 03-17-2016, 09:37 AM

The problem could still be: the Control Board, the Relay or the OBC activation.

The control board appears to use a Solid State Relay, so You cannot just test the contacts with an ohmmeter.

Do the following test to isolate the problem.

Disconnect the AC cord.

Disconnect the DC cord 3-pin connector from the cart.

Disconnect the 2 small (0.187") quick connectors from the relay coil (blue and red wires).

Set Your meter to 20kΩ setting.

Measure the resistance on the Relay small quick tabs.

You should get approximately 2.5kΩ resistance.

If You get and Open circuit (0L on the meter), the Relay is BAD.

If the Relay coil shows the approximate resistance:

Connect the red wire back into the relay.

Leave the blue wire disconnected from the relay coil.

Disconnect the blue wire from the DC cord that is connected to the top of the control board (3rd image) and plug it directly to the relay coil small tab where the other blue wire was connected.

Plug the DC cord 3-pin connector back into the cart.

The relay should "Click" after a few seconds.

If the relay does click, the control board is BAD.

If the relay does not click, the OBC activation is not working.

gilbertj77080 · 03-17-2016, 10:55 AM

thanks, will follow those steps and see what i get

TahoeDawgZ71 · 03-17-2016, 12:51 PM

Thanks Sergio, I was about to jump on this one but I see you've handled it.

gilbertj77080 · 03-17-2016, 05:35 PM

open on the relay, so ill order a relay and see what happens then, thanks

Sergio · 03-17-2016, 05:50 PM

That will be a lot cheaper than the control board...

RevolutionGolfCars.com is a good source for the part.

gilbertj77080 · 03-22-2016, 03:26 PM

i installed the new relay, now it looks like it is charging steady, no off/on thing. keep my fingers crossed, lol thanks for the advice

Harlow42 · 04-18-2019, 10:17 PM

http://www.buggiesgonewild.com/attac...receptacle.jpg

With just the charger head plugged into the cart's charge receptacle.
In this picture,
pin #3, (Grey Wire) has 50.2 volts
pin #4, (Red Wire) has 0 voltage
pin #5, (Black Wire) has 12.5 volts

Measuring voltage at the pins on the cart's receptacle, with no charger attached,
I still get 50.2 volts on the grey wire, and no voltage on the red wire and 12.5 volts on the black wire coming from the OBD

Inside the PowerDrive charger, with just the just the charger's charge head plugged into the cart's recepticle:
I pulled the red & blue wires off the 48v DC relay and I measure 50.2 volts on the red wire using the carts battery negative for ground.

If I remove all leads from the relay and use two jumpers on the relay's coil, red to carts battery pack for positive and blue to carts battery pack for negative, the relay will click on, (applying 50.2 volts) and I have continuity across the relay's pins for the primary coil lead, to the cicuit breaker, ground pin.

If I were to jump a 10ga wire from the #5 pin (OBD side), the black wire on the charge recepticle, to the pack negative, as per trouble shooting proceedures, I would be placing 12.5 to the battery ground.
The relay in the charger cannot work without having a cart ground.
My receptacle (black wire) ground is showing voltage, not cart ground?

I can install a jumper in the charger, (from the charger's fuse, to the transformer lead, I can then charge the cart's batteries.
but the cart's low battery light keeps sending a fault code (one short and one long).
Re-setting the OBD only cures this for one charge cycle.

I did a continuity check on the two fuses at the charger receptacle, both were okay.
I checked the black negative OBD wire, continuity was okay.
I used the continuity check on the charger's internal fuse, it was okay.
My OBD only has the standard black wire from the #6 battery.
The battery pack is three months old, & the controller is 5 years old.
The cart has a voltage reducer, it is 48v, 30 amp, powered 'on' by the ignition key.
I disconnected all accessories, including the voltage reducer and headlights and taillights and I still get 12.5 volts on the #5 pin in the charging receptacle, which comes from the OBD cabling assembly.

Club Cart - 1999 DS regen
Serial Number:

Motor:
Part #: 101854501
Model #: 5BC59JBS6251C
Date Code: RPN N
Bar Code: MOTO4271999054005
Voltage: 48
Horse Power: 3.2
Federal Supply Code: #88422

Controller:
MFG: GE
Part #: IC3645SH4D222C2
Amps: 220
Serial #: SH4D012194F
Date: 9/16/2014

Charger:
PowerDrive 2
Model #: 17930-11
Date Code #:11/97
Serial @: 110705269

Does anyone have any other checks to use to verify my issues?

03-16-2016, 07:39 PM	#1
gilbertj77080 Not Yet Wild Join Date: Nov 2014 Location: houston tx Posts: 9	powerdrive 17935 charger issues i have a powerdrive on board charger 17935. it don't turn on and charge is the issue. i'm running a 4 12vdc battery set up. the batteries are 46.5vdc, plug in the charger and nothing. if i jump the wires on the black relay then it charges. i was told two theories, 1 is the relay is bad and the other is that the electronic timer board is bad. any thoughts? thanks in advance

03-22-2016, 03:26 PM	#7
gilbertj77080 Not Yet Wild Join Date: Nov 2014 Location: houston tx Posts: 9	Re: powerdrive 17935 charger issues i installed the new relay, now it looks like it is charging steady, no off/on thing. keep my fingers crossed, lol thanks for the advice

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03-17-2016, 10:55 AM	#3
gilbertj77080 Not Yet Wild Join Date: Nov 2014 Location: houston tx Posts: 9	Re: powerdrive 17935 charger issues thanks, will follow those steps and see what i get

03-17-2016, 12:51 PM	#4
TahoeDawgZ71 revolutiongolfcars.com Join Date: Mar 2010 Location: Golf Car Capital of The World... Augusta, Georgia Posts: 10,224	Re: powerdrive 17935 charger issues Thanks Sergio, I was about to jump on this one but I see you've handled it.

03-17-2016, 05:35 PM	#5
gilbertj77080 Not Yet Wild Join Date: Nov 2014 Location: houston tx Posts: 9	Re: powerdrive 17935 charger issues open on the relay, so ill order a relay and see what happens then, thanks

03-17-2016, 05:50 PM	#6
Sergio Gone Wild Join Date: Sep 2012 Location: Charlotte, NC Posts: 9,329	Re: powerdrive 17935 charger issues That will be a lot cheaper than the control board... RevolutionGolfCars.com is a good source for the part.

04-18-2019, 10:17 PM	#8
Harlow42 Not Yet Wild Join Date: Mar 2018 Location: Indianapolis, Indiana Posts: 55	Re: powerdrive 17935 charger issues http://www.buggiesgonewild.com/attac...receptacle.jpg With just the charger head plugged into the cart's charge receptacle. In this picture, pin #3, (Grey Wire) has 50.2 volts pin #4, (Red Wire) has 0 voltage pin #5, (Black Wire) has 12.5 volts Measuring voltage at the pins on the cart's receptacle, with no charger attached, I still get 50.2 volts on the grey wire, and no voltage on the red wire and 12.5 volts on the black wire coming from the OBD Inside the PowerDrive charger, with just the just the charger's charge head plugged into the cart's recepticle: I pulled the red & blue wires off the 48v DC relay and I measure 50.2 volts on the red wire using the carts battery negative for ground. If I remove all leads from the relay and use two jumpers on the relay's coil, red to carts battery pack for positive and blue to carts battery pack for negative, the relay will click on, (applying 50.2 volts) and I have continuity across the relay's pins for the primary coil lead, to the cicuit breaker, ground pin. If I were to jump a 10ga wire from the #5 pin (OBD side), the black wire on the charge recepticle, to the pack negative, as per trouble shooting proceedures, I would be placing 12.5 to the battery ground. The relay in the charger cannot work without having a cart ground. My receptacle (black wire) ground is showing voltage, not cart ground? I can install a jumper in the charger, (from the charger's fuse, to the transformer lead, I can then charge the cart's batteries. but the cart's low battery light keeps sending a fault code (one short and one long). Re-setting the OBD only cures this for one charge cycle. I did a continuity check on the two fuses at the charger receptacle, both were okay. I checked the black negative OBD wire, continuity was okay. I used the continuity check on the charger's internal fuse, it was okay. My OBD only has the standard black wire from the #6 battery. The battery pack is three months old, & the controller is 5 years old. The cart has a voltage reducer, it is 48v, 30 amp, powered 'on' by the ignition key. I disconnected all accessories, including the voltage reducer and headlights and taillights and I still get 12.5 volts on the #5 pin in the charging receptacle, which comes from the OBD cabling assembly. Club Cart - 1999 DS regen Serial Number: Motor: Part #: 101854501 Model #: 5BC59JBS6251C Date Code: RPN N Bar Code: MOTO4271999054005 Voltage: 48 Horse Power: 3.2 Federal Supply Code: #88422 Controller: MFG: GE Part #: IC3645SH4D222C2 Amps: 220 Serial #: SH4D012194F Date: 9/16/2014 Charger: PowerDrive 2 Model #: 17930-11 Date Code #:11/97 Serial @: 110705269 Does anyone have any other checks to use to verify my issues?