Club Car V-GLIDE, Maintenance Service Supplement

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ELECTRICAL COMPONENTS Solenoid
2004 V-Glide 36-Volt Electric Vehicle Maintenance and Service Supplement Page 12-5
12
SOLENOID
See General Warning, Section 10, Page 10-1.
The solenoid is mounted in front of the no. 3 and no. 4 batteries. See Figure 10-1, Section 10, Page 10-2. It
has two sets of terminal posts. The two large terminal posts are power contact terminals and the two small
posts are activating coil terminals.
Testing the Solenoid
See Test Procedure 5, Section 11, Page 11-10.
See Test Procedure 10, Section 11, Page 11-15.
See Test Procedure 11, Section 11, Page 11-15.
Solenoid Removal
1. Disconnect the battery cables as instructed. See WARNING “To avoid unintentionally starting...” in
General Warning, Section 10, Page 10-1.
2. Disconnect all wires from solenoid.
3. Remove the two thread-rolling screws securing the solenoid to the vehicle.
Solenoid Installation
1. Position the solenoid with the small posts toward the front of the vehicle. Install one of the mounting
screws through the driver-side hole on the solenoid base and into the corresponding hole in the mounting
plate (Figure 12-4, Page 12-6). Tighten screw to 50 in-lb (7.3 N·m).
2. Install passenger-side screw and tighten to 50 in-lb (5.6 N·m) (Figure 12-4, Page 12-6).
3. Install diode assembly onto small solenoid posts. Make sure the direction of the diode is correct. The red
insulated terminal of the diode assembly should be installed on the same post that the 18-gauge yellow
wire is attached, and the clear insulated terminal of the diode assembly should be installed on the same
post that the 18-gauge green wire is attached (Figure 12-5, Page 12-6). See following WARNING.
∆
WARNING
• Do not damage snubber when mounting solenoid.
• Install both mounting screws. Failure to install both screws can result in solenoid and
electrical system damage and failure.
4. Attach snubber assembly to frame on either the passenger or the driver-side of the solenoid using a wire
tie and cable tie mounting base (Figure 12-4, Page 12-6).
5. Attach wiring to solenoid. Connect black wire from snubber to the large rear solenoid post that the 6-
gauge white wire (from the speed switch) is attached. Connect red wire from the snubber to the large
front post that the 18-gauge and 6-gauge white wires are attached. See following CAUTION.
CAUTION
• Make sure the wires are routed so the wire from the FORWARD and REVERSE rotor does not
pull on other wires as the Forward/Reverse handle is shifted.
6. Using a low profile wrench to hold the inner nuts on the solenoid posts in place, tighten the outer nuts of
the large posts to 100 in-lb (11.3 N·m). Tighten the outer nuts of the small solenoid posts to 4 in-lb (0.5
N·m) (Figure 12-5, Page 12-6). See following WARNING.