EZGO 36v DCS electric only 25v under load on A1 to motor?

Steveleavitt7777

36v system. All batteries and connections are good. Load test each battery is good! Has a new solenoid and all other electrical test are good. read switch and micro switches test good.
A1 on controller to the motor shows 37.5v and when you push pedal goes down to 25v. Same at A1 motor connection. Motor/wheel jerks and turns a little (I assume because of low voltage). Can get the tire turning by spinning it and cart works right. speeds up and slow down correctly.
Do I have a bad controller? Motor test out ok and I have taken it apart and cleaned it and it looks fine. Help!!! Thanks.

BGW

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Great white north

Do you have both B-and B+ voltage present at solenoid ? do you hear the solenoid click ?
The B- voltage comes from the controller! If no voltage ,controller issue
I would by-pass reed switch can always give issues ! , if done correctly !
Also use the search tab on site regarding testing ITS module ? And correct voltage readings ?
Cheers !

Steveleavitt7777

Thanks great white. yes solenoid clicking and correct voltage on both sides. I am suspect of the ITS also. Have done all the volt test possible and ITS does show bad. (White wire shows 13.9 plugged in and 14.2 unplugged)(bad). Does it control how much voltage goes out of controller? I have bypassed the read switch already. I just put what I thought was a good used ITS on it. But maybe I got shafted on that deal.

JohnnieB

You are measuring directly across the control element of the controller, so it will decrease when the pedal is pushed.
To measure voltage applied to motor, measure the A2 terminal on motor.
It will start at Zero and increase in voltage.

You might have a bad controller or ITS (throttle) if the voltage at A1 is not going all the way to Zero.

Also check the F1 & F2 cables. see attached.

Attached Images

Worn field wire insulation.jpg (593.6 KB, 0 views)

Steveleavitt7777

Great thanks. I will check it when I get back home this afternoon. I don't think with of my motor a1 or a2 are at zero. I will check.

JohnnieB

Measure from A1 to A2. Should go from Zero when solenoid fist clicks, up to full pack voltage if the Cables, Connections and Contacts are good.

From F1 to F2, you should get about 8V with pedal on floor.

Steveleavitt7777

OK guys here is the volts reading on the motor. I have A1 S1 A2 S2 markings on the posts.
All readings are in run mode, key on

A1 nor A2 have zero reading. pack negative to voltmeter red reads 38 volts on both contacts. When I push the peddle A2 goes down to 35.5. A1 starts at 38 down to 36 when solenoid engages and down to 26 with peddle all the way down.

testing a1 to s1 as the peddle is being pushed goes from 38 down to 26
A2 to S2 as you push the peddle goes from 38 to 32

when they are supposed to be at zero where do you connect the negative lead on the volt meter?

Does this tell you anything?

Great white north

Always put negative lead of DVM on negative post of pack voltage , when doing readings , move positive lead of DVM to different test points

Steveleavitt7777

OK that is what I did for all the readings in previous post

Great white north

I would suggest there is a ITS module issue
Maybe Johnny B can add some more possible problem areas !
Cheers !