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Unread 05-26-2016, 10:20 PM   #1
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Default Powerdrive 2 charger help!

Powerdrive 2 charger on a 02 series DS will not charge. The on-board computer has been replaced. I purchased the rebuild kit from Tahoe for the charger which replaced the breaker, relay, and rectifier. You can bypass the relay with a jumper and will work fine. I also replaced the receptacle at the cart because it was loose and sloppy. What do I need check to find the problem? Thanks.
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Unread 05-27-2016, 07:46 AM   #2
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Any ideas? What should the voltage be at the receptacle on the cart? I get pack voltage on one and about 10 volts on the other. I'm assuming that is the sensing wire?
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Unread 05-27-2016, 09:00 AM   #3
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Default Re: Powerdrive 2 charger help!

You can make a few quick voltage tests to find the problem:

Set the meter to 200vDC.


Measure from Pack Positive to Negative Socket on the charger receptacle.
You should have a few volts less than pack voltage.

Measure from Positive Socket on the charger receptacle to Pack Negative.
You should have pack voltage.

Measure from Positive Socket on charger receptacle to Sense Wire Socket on the charger receptacle.
You should have about 42v (this can vary depending on your meter's impedance).

If all of those voltages are OK and the charger relay is not clicking once You plug the DC cord into the cart, the issue is on the charger side of the relay circuit (DC plug, cable or wiring connections).
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Unread 05-27-2016, 09:51 AM   #4
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Thanks Sergio! I'll check those voltages this afternoon.
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Unread 05-27-2016, 12:37 PM   #5
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Ok Sergio, voltage at the receptacle is negative pin to positive pin, 39 volts positive to the gray sensing wire is 47 volts, pack voltage is 50.4. And I do have pack voltage from b- to the positive in the receptacle. All the voltage translates into the charger, so I think the cord is good. Could the new relay be bad? Rectifier? How do you check the rectifier?
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Unread 05-27-2016, 12:53 PM   #6
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Default Re: Powerdrive 2 charger help!

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positive to the gray sensing wire is 47 volts
Leave the charger AC plug disconnected.

Plug the DC cord into the cart.

Disconnect the two small terminals (3/16) from the relay and measure the voltage on those 2 wires, it should match the voltage You got in the measurement above.

If it does and the relay is not clicking, then the relay is bad.
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Unread 05-27-2016, 01:25 PM   #7
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Ok I measured between the negative wire at the dc fuse to the small plugs on top of the relay I get 39 volts on the white wire and nothing on the blue one. There is a red jumper connecting the two is that right? Should there be voltage on both wires since they are jumped together?
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Unread 05-27-2016, 01:35 PM   #8
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Correction, I now get 47 volts between the 2 small wires on top of the relay.
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Unread 05-27-2016, 01:48 PM   #9
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Default Re: Powerdrive 2 charger help!

The voltage reading should be between the Blue and the White wires.

There is a diode in that small red wire between the Blue and White wires above that connect to the relay coil.

The relay should click with 47v You measured on the coil.

Set your meter to 20kΩ scale and measure the resistance on the small relay tabs without the Blue and White wires connected.

You should have approximately 2.4kΩ (2400Ω) resistance, if You get an open line 0L, the relay is bad.
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Unread 05-27-2016, 02:39 PM   #10
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I'm getting anywhere from 3-4k between the 2 small wires. Could the diode be bad?
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