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Unread 12-13-2017, 08:33 PM   #1
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Default 36v solenoid refurbishment

36v 1984 ds 2 bad solenoids repair on first one total success, I will take pics and
document procedure on next one if there is interest.
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Unread 12-13-2017, 08:41 PM   #2
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Default Re: 36v solenoid refurbishment

I have two bad solenoids around- Iím following.


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Unread 12-18-2017, 05:51 PM   #3
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Default Re: 36v solenoid refurbishment

Here we go 3rd solenoid, this one has heat damage(cracked case)
First job is to grind or drill rivets, on plastic side, tap out the 3 rivets, leave one
rivet attached it will allow you to rotate bottom plate away from body. 1st pic
Remove cork and metal spacer. 2nd pic
Carefully bend coil wires to upright position, pay attention to coil orientation to
solenoid case. Note:my coil resistance was about 59 ohms, you must have a good coil or this process is worthless, Use a soldering iron to separate coil wire from terminal wire, coil wire is much thinner than terminal wire so it wraps around straight terminal wire. 3rd pic
Next remove coil+plunger, then remove steel sleeve(labeled #1) by carefully using very small screwdriver and slide out of solenoid case, then remove contact
guide and contact with spring. 4th pic
I had a lot of carbon dust fall out of unit when I disassembled, Contact assy was pitted severely so I scraped,sanded, and cleaned, then used solder paste and soldered pits with 60/40 solder, then sanded flat and polished with scotchbrite pad, I used screwdriver to scrape terminal contacts and scotchbrite pad on end of screwdriver which are mounted in case. 5th pic
I cleaned everything with alcohol and lightly lubed with wd-40, reassembled
in reverse from disassembly, It really is not hard just need to be patient.
My case was fractured and used jb-weld to fix. 6th pic
Testing coil was 58.5 ohms, and had 0 ohms on contacts.(before disassembly contacts measured open when coil was energized)
Hope this helps someone, I can do this procedure in about 3 hours and its free.
Attached Images
File Type: jpg plate.jpg (93.3 KB, 0 views)
File Type: jpg cork.jpg (64.7 KB, 0 views)
File Type: jpg unsoldered coil.jpg (61.1 KB, 0 views)
File Type: jpg soleoid 1.jpg (72.2 KB, 0 views)
File Type: jpg contact.jpg (67.7 KB, 0 views)
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Unread 12-18-2017, 05:53 PM   #4
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Default Re: 36v solenoid refurbishment

6th pic
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Unread 12-19-2017, 07:44 AM   #5
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Default Re: 36v solenoid refurbishment

This is great! Nice tutorial! But .... You can buy these new on eBay for about $15 each. Right now, you can buy a 5 pack with free freight for $52. When I had 2 go bad, That is what I did.
Jack
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Unread 12-19-2017, 08:01 AM   #6
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Default Re: 36v solenoid refurbishment

I have successfully done a few of these myself. The exact same solenoids in 12v and 24 v are used on a lot of the grass machinery i work on and it is very satisfying to save a few quid/bucks for just pitted and dirty contacts.

If any one else decides to try this, be warned, take note of the exact orientation of the steel sleeve when refitting or it wont go back together.

Well done.
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Unread 12-19-2017, 08:48 AM   #7
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Default Re: 36v solenoid refurbishment

Gravelydude you are right, I was curious of failure and self satisfaction of repair, Cartmaster
excellent point, should use sharpie and mark parts for orientation.
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Unread 12-19-2017, 11:09 AM   #8
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Default Re: 36v solenoid refurbishment

Gravelydude do you have link thats cheap?
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Unread 12-19-2017, 03:27 PM   #9
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Default Re: 36v solenoid refurbishment

Once you file or sand the silver plating off the contacts they won't last very long. Best to replace.
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Unread 12-19-2017, 08:29 PM   #10
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Default Re: 36v solenoid refurbishment

https://www.ebay.com/itm/36-Volt-Sol...xYqzvk&vxp=mtr
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