Section 16A - Motor (Model 5Bc59Jbs6390); General Information; Motor Identification; External Motor Testing - Club Car DS Villager 4 Maintenance And Service Manual Supplement

SECTION 16A – MOTOR (MODEL 5BC59JBS6390)
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DANGER
• See General Warning, Section 10, Page 10-1.
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WARNING
• See General Warning, Section 10, Page 10-1.

GENERAL INFORMATION

The electric vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. The shunt-wound
motor is designed for use on IQ System vehicles only. It is recommended that motors requiring major repair
be sent to a qualified motor repair shop; however, there are many relatively simple tasks that can be per-
formed by a technician with general knowledge and experience in electric motor repair.

MOTOR IDENTIFICATION

There are two types of motors used in IQ System vehicles: 1) Model 5BC59JBS6390 (gray housing), and 2)
EJ4-4001 and EJ8-4001A (both with black housing). Do not attempt to service a motor that has not been
properly identified. If the motor cannot be properly identified, contact your local dealer or distributor.

EXTERNAL MOTOR TESTING

The following tests can be performed without disassembling the motor using a multimeter or continuity tester.
NOTE: Tag the motor wires for identification before disconnecting.
TEST PROCEDURE 1 – INTERNAL SHORT CIRCUITS
See General Warning, Section 10, Page 10-1.
1. Disconnect the batteries and discharge the controller. See Disconnecting The Batteries on page 10-3.
2. Disconnect wires from terminals on motor using two wrenches to prevent posts from turning.
3. With a multimeter set to 200 ohms, place black (–) probe on motor housing. Scratch through paint to
ensure a good connection. Place red (+) probe on A1, A2, F1, and F2 terminals respectively. Multimeter
should indicate no continuity between the motor housing and all individual terminals. If readings are
incorrect, motor will need to be removed from the vehicle and repaired by a qualified technician. See
Motor Removal on page 16a-2.
3.1. An incorrect reading from the A1 or A2 terminal indicates three possible problems: a grounded A1
or A2 terminal, a grounded wire in the brush area, or a grounded armature/commutator. An incor-
rect reading for the F1 or F2 terminal indicates a possible grounded F1 or F2 terminal or field coil.
2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement
16A
Page 16a-1