Club Car Carryall 1, Maintenance And Service Manual Supplement, Page: 136 / 176

MOTOR (MODELS EJ4-4001 AND EJ8-4001A) External Motor Testing
Page 16b-2 2008-2011 IQ System Electric Vehicle Maintenance and Service Supplement
16B
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, S1, and S2 terminals respectively. Multimeter
should indicate no continuity. If readings are incorrect, motor will need to be removed from the vehicle
and repaired by a qualified technician.
See Motor Removal on page 16b-3.
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 S1 or S2 terminal indicates a possible grounded S1 or S2 terminal or field coil.
TEST PROCEDURE 2 – ARMATURE CIRCUIT OPEN
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 the A1 and A2 terminals on the motor using two wrenches to prevent posts from
turning. Set a multimeter to 200 ohms and place the red (+) probe on the A1 terminal and black (–) probe
on the A2 terminal. The multimeter should indicate continuity. If the reading is incorrect, a possible open
or poor contact in a brush assembly and/or open armature windings may be the cause. The motor will
need to be removed from the vehicle and repaired by a qualified technician.
See Motor Removal on
page 16b-3.
TEST PROCEDURE 3 – FIELD CIRCUIT OPEN
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 the S1 and S2 terminals on the motor using two wrenches to prevent posts from
turning. Set a multimeter to 200 ohms and place the red (+) probe on the S1 terminal and the black (–)
probe on the S2 terminal. The multimeter should indicate continuity. If the reading is incorrect, a possible
open field coil or bad connections at the terminals may be the cause. The motor will need to be removed
from the vehicle and repaired by a qualified technician.
See Motor Removal on page 16b-3.
MOTOR TERMINALS
CONTINUITY TEST
RESULT
A1 to A2
F1 to F2
Continuity
A1 to F1
A1 to F2
No Continuity
A2 to F1
A2 to F2
No Continuity
A1 to Ground
A2 to Ground
No Continuity
F1 to Ground
F2 to Ground
No Continuity