Powerwise charger problem

[busman9]

I have a powerwise charger,when i hook it to the cart the charger hums but the gauge only reads 5 amps. I checked at the batteries and when the charger is on there is only a 5 amp increase at the batteries. I hooked another charger to the cart and the gauge went to 15 amps. Please help johnnie!:

[JohnnieB]

Check the diodes.
If one is bad, replace both. 1N1184 diodes will work.


Here is a service manual for PW and PW+ chargers.
If that isn't what you have, post a picture of the faceplate.

[busman9]

Thanks johnnie,i am going to the clubhouse today will check and post when i come home

[busman9]

Johnnie, Tested the diodes-test good 50A fuse blown--replace with another 50A fuse (not the same kind) popped the fuse right away. What test is next? Thanks

[JohnnieB]

If it is blowing the 50A fuse:
1. One or both of the diodes is bad.
2. The wires in the output cable are shorted together.
3. The wires between the cart's charging receptacle and battery pack are shorted together.
4. One or more batteries in pack is bad.

[busman9]

Johnnie,The flow chart goes to the amp meter. Can the amp meter be shorted popping the fuse. The other things you stated all check good. I have hooked another charger to the cart and it charged.

[busman9]

Johnnie,The test was 91V. Could the capacitor still be shorted? Ohm reading across top of the capacitor is 1.6 ohm and the wires on the capacitor have been hot. Thanks

[JohnnieB]

If the 91V reading was with the capacitor connected, it indicates that both the transformer and capacitor are good.
(Also, if capacitor was shorted, it would most likely has gunk spewing out of it.)

I don't see an "R" suffix on the 1N11889 part number, so they shouldn't be causing the sparking. (Looks like there is room for the stud ends between the heatsink an circuit board, so I'd lose the old mounting bracket the original diodes were press-fit into and bolt the new diodes tight to just the aluminum heatsink.)

The white and black wires from the output cable appear to be connected to the right places inside the charger, but where are they connected in the plug that plugs into the cart?

When plugged into cart, they should match up with the white and black wires in the cart's charge receptacle. See attached picture.

Try this:
Connect the diodes, capacitor and other stuff inside the charger as they should be (It looks like they were in the pictures you posted)

By-pass the relay and without plugging charger into cart, plug charger into AC power.

If it sparks or blows the fuse, the output cable is shorted someplace.
If it just sits there and hums, there is a high probability the output wires are reversed in the output plug.

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Does the DPI work with the cart?

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If all else fails, box up the charger and send it to me, I'll find a good home for it.

[busman9]

The dpi charger and other powerwise chargers work fine on the cart

[JohnnieB]

Originally Posted by busman9

The dpi charger and other powerwise chargers work fine on the cart

That narrows it down to the charger and having 91VAC between the wires going to the diodes pretty much narrows it down to the diodes, heatsink, output cable or output plug.

Getting closer to solving the mystery.