Club Car 1996 DS Golf Car Gasoline, Service Manual

Page: 382 / 544

Page 20-32
20B
E
The Solenoid, Continued:
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 on the solenoid as shown in the wiring diagram (Figure 20-2, Page 20-3, or Figure 20-3,
Page 20-4).
3. Install diode and resistor as shown in wiring diagram (Figure 20-2 or 20-3).
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.
Removing the Diode
The diode assembly is connected to (and positioned between) the two small No. 10 posts (activating coil
posts) on the solenoid.
1. Disconnect batteries (Figure 20-1, Page 20-2).
2. Discharge the controller (See instructions in Warning Box on the Page 20-25).
3. Remove the two nuts attaching diode assembly to the solenoid.
4. Remove diode assembly.
Testing the Diode
1. Using a VOM, check for continuity between both diode terminals. Reverse the tester leads and again
check for continuity.
2. A diode is designed to conduct current in one direction only. If a diode shows continuity in both direc-
tions or does not show continuity in either direction, replace diode assembly.
Installing the Diode
1. Install diode assembly to small No. 10 solenoid studs.
2. Ensure that the direction of the diode is correct. The red insulated terminal of the diode assembly
should be installed on the same stud to which the 18 gauge red wire (with insulated terminal) is
attached, and the uninsulated terminal of the diode assembly should be installed on the same stud to
which the 18 gauge yellow wire is attached (Figure 20-2, Page 20-3, or Figure 20-3, Page 20-4).
3. Install remaining wires to studs as shown (Figure 20-2 or 20-3). Install and tighten two No.10 nuts to
posts. Torque to 17-20 in.lbs. (2.0/2.3 N-m).
RESISTOR - (SOLENOID)
A 250 ohms resistor is placed across the contacts to keep the capacitors in the controller charged. This
reduces arcing on the contacts of the solenoid. Whenever a solenoid fails, this 250 ohms resistor should be
checked.
Removing the Resistor
1. Disconnect batteries (Figure 20-1, Page 20-2).
• FAILURE TO DISCHARGE THE CONTROLLER COULD RESULT IN A SHORT CIRCUIT SHOULD
THE WRENCH OR RATCHET TOUCH THE LARGE POST DURING REMOVAL OR INSTALLA-
TION OF THE DIODE ASSEMBLY.
WARNING