Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 339 / 544

Page 19-23
E
19B
The Solenoid, Continued:
Testing the Solenoid
See Test Procedures 5, Page 19-11, and 9 and 10, Page 19-13.
Removing the Solenoid
1. Disconnect all wires from the solenoid.
2. Remove the two screws, washers, and nuts attaching the solenoid to the vehicle.
Installing the Solenoid
1. Position the solenoid and install the two mounting screws, washers, and nuts. Tighten the screws to 66
in.lbs. (7.5 N-m).
2. Connect the wires as shown in the wiring diagram on Page 19-3 (Figure 19-2). See CAUTION below.
RESISTORS
The resistors are attached to the resistor mounting board which is located behind the batteries.
Testing the Resistors
See Test Procedure 6, Page 19-11.
Removing the Resistors
1. Loosen (do not remove) the nuts (1) that secure the resistors (R1 - R5) to the mounting board and then
slide the resistors out from under the washers (3) (Figure 19-13, Page 19-24).
Installing the Resistors
1. Position the resistor ends under the washers (3) and tighten the nuts to 90-100 in.lbs. (10/11 N-m). See
the CAUTION below and at the top of page 19-24, and the NOTE at the top of page 19-25. See the
chart on page 19-25.
• WHEN MAKING ELECTRICAL TESTS OR REPAIRS, ALWAYS:
- WEAR SAFETY GLASSES OR APPROVED EYE PROTECTION.
- REMOVE THE KEY.
- PUT THE FORWARD AND REVERSE SWITCH IN NEUTRAL.
- DISCONNECT THE BATTERIES AS SHOWN (FIGURE 19-1, PAGE 19-2).
• FOLLOW ALL PROCEDURES EXACTLY AS INSTRUCTED.
• SEE THE SAFETY WARNINGS ON PAGE 19-1.
• MAKE SURE THE WIRES ARE ROUTED SO THAT THE WIRE FROM THE FORWARD AND
REVERSE ROTOR DOES NOT PULL ON OTHER WIRES AS THE FORWARD AND REVERSE
LEVER IS SHIFTED.
• BE SURE THE MOTOR WIRES ARE SECURED IN WIRE TIES SO THAT THEY CANNOT COME
INTO CONTACT WITH THE RESISTORS.
WARNING
CAUTION
CAUTION