Testing The Solenoid - Club Car 1995 Golf Car Maintenance Service Supplement

THE SOLENOID
The solenoid is located on the passenger's side fender well behind the battery compartment. The solenoid
has two sets of posts; two 5/16 inch posts (power contact posts) and two small No. 10 posts (activating coil
posts).
WARNING
• WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS:
• WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION.
• REMOVE KEY.
• DO NOT WEAR LOOSE CLOTHING. REMOVE JEWELRY SUCH AS RINGS, WATCHES,
CHAINS, ETC. BEFORE SERVICING VEHICLE.
• PUT F&R SWITCH IN NEUTRAL.
• DISCONNECT BATTERIES AS SHOWN IN FIGURE 17-1, PAGE 17-2.
• FOLLOW ALL PROCEDURES EXACTLY AS STATED.
DANGER
• TURN KEY SWITCH TO OFF AND REMOVE KEY, PUT THE F&R SWITCH IN NEUTRAL,
AND DISCONNECT THE BATTERY CABLES AS SHOWN IN FIGURE 17-1, PAGE 17-2. FAIL-
URE TO DO THIS MAY CAUSE THE VEHICLE TO RUN OVER YOU, RESULTING IN SEVERE
INJURY OR DEATH!

Testing the solenoid:

See Test Procedure 7, Page 17-16.
Removing the solenoid:
1. Disconnect batteries (Figure 17-1, Page 17-2).
2. Discharge the controller (See instructions in Warning Box on Page 17-25).
WARNING
• FAILURE TO DISCHARGE THE CONTROLLER COULD RESULT IN A SHORT SHOULD THE
WRENCH OR RATCHET TOUCH THE LARGE POST DURING REMOVAL OR INSTALLATION OF
THE RESISTOR OR DIODE ASSEMBLY.
3. Disconnect all wires from solenoid. Remove resistor assembly and diode assembly.
Installing the solenoid:
1. Install the solenoid to the mounting plate and torque to 66 in.lbs. (7.5 N-m). The solenoid does not have
to be oriented in any particular manner.
2. Install wires as shown in wiring diagram (Figure 17-2, Page 17-3, or Figure 17-3, Page 17-4).
3. Install diode and resistor as shown in wiring diagram (Figure 17-2 or 17-3).
THE DIODE - (SOLENOID)
A diode is placed across the solenoid activating coil to allow the field to collapse and prevent limit switch fail-
ures. If limit switches are failing, the diode should be checked for correct orientation.
17-31