Help with 2001 Series DS build

DJBlade · 03-01-2015, 07:58 AM

I bought a "fixer upper". She runs slow up slight grades (8 - 10 mph) , but has torque to keep her moving even fully loaded. (firewood on back and 2 passengers) I am looking for a little more speed. Here is where I am at with the build now and looking for input or suggestions:

Battery pack seems fine. Charges up (52 volts) and all seem fine under load (none below 7.9) 2 year old batteries. Water levels good.

Upgraded MCOR to MCOR4 conversion kit
New HD Solenoid installed
Altrax 400 amp controller installed and tuned correctly to get 100% throttle
4awg wires on batteries. (stock wires to motor and F/R switch)
Stock F/R switch
Stock Series motor
Correct Air pressure in tires
HD springs on rear
Tow settings correct and worn front end parts replaced

Here is what I think I need to upgrade. PLEASE advise if I am either in "overkill" mode or not thinking this through correctly.

Order HD F/R switch
Order 4awg to motor and F/R switch
Upgrade motor to a high speed/torque motor

Also any suggestions on motor would be helpful too.

mrgolf · 03-01-2015, 09:10 AM

You may get a big improvement with the cable upgrade, and the f&r switch. You may not need the motor just yet. I would like to hear how much those changes do before you change the motor. In fact I think just the cables may make quite a difference. I'm trying to con you into doing those checks and letting us know the results.

DJBlade · 03-01-2015, 09:39 AM

Will do. I am ordering the F/R switch and cables as we speak. Thanks!

DJBlade · 03-03-2015, 06:14 AM

Well this sucks. Cart just died. ALTRAX shows 7 blinking light,solenoid clicks, and goes nowhere. Could it be the F&R switch? It original and with the extra amps I feel that may be the culprit. Thankfully I have one ordered. One other thing....if I hold the pedal down while it isn't moving I get 4 red lights on controller....thermal detection. I'm guessing a buildup of excess heat since amperage won't pass through switch to motor?!? Any help or thoughts appreciated.

Golfdog · 03-05-2015, 03:57 PM

As you have a Series Motor increasing Controller amps won't give more speed, you need to either swap motor for one wound for speed or increase the voltage thu the standard motor. a 36v motor would give you a nice improvement.

DJBlade · 03-05-2015, 04:59 PM

Well ain't this crazy! As I said before, the cart died on me and I have a F&R switch on the way.....which is good. I need one anyway. But something inside my pea brain told me to check, check, and recheck the battery cables. Well, I took it a step further and replaced them with new ones.....made new ones. Clean terminals, clean connections and VIOLA....cart runs again. Tell me it ain't that easy!!

wards75 · 03-05-2015, 05:48 PM

Glad you got the cart up and running again. The other day, I changed out 2 ring connectors on the F&R switch and it didn't run afterwards. Was told by a forum member or 2 to check my wiring that something was crossed and it was but the funny thing is, I didn't unplug anything until after it wouldn't run...but it was a crossed wire on the micro switches...strange for sure.

DJBlade · 03-09-2015, 04:00 PM

OK, I need some advise on this one please. I got this cart at a deal knowing it didn't run. I figured I could fix it but it is whipping my butt. Here is what I have done and what the symptoms are.

Cart will intermediately go forward fine and reverse fine. Ever so often it won't budge but the solenoid will click...just sits there. Slamming foot on accelerator and F&R back and forth and it takes off again and runs fine.

1. Upgraded MCOR to MCOR4
2. Installed HD F&R switch
3. 4 AWG cables nearly throughout ( yet to replace cables from F&R to motor and controller
4. New HD Solenoid
5. 400 Amp Alltrax Controller

What could be causing the cart not to run but to have the solenoid click? I am at a loss. Maybe the new MCOR4 has failed? Any experts on a 2001 DS out there that can help would be greatly appreciated. I want to feel comfortable taking this cart out on hunts with me.

Sergio · 03-09-2015, 04:19 PM

The only thing I can think of it would be micro switch #3 (the 1/2 speed one)

http://www.buggiesgonewild.com/attac..._with_mcor.jpg

Just by-pass it to eliminate the possibility.

DJBlade · 03-09-2015, 04:39 PM

Well those are all new too. Should have mentioned that.

03-01-2015, 07:58 AM	#1
DJBlade Gone Wild Join Date: Dec 2011 Location: Columbia, South Carolina Posts: 258	Help with 2001 Series DS build I bought a "fixer upper". She runs slow up slight grades (8 - 10 mph) , but has torque to keep her moving even fully loaded. (firewood on back and 2 passengers) I am looking for a little more speed. Here is where I am at with the build now and looking for input or suggestions: Battery pack seems fine. Charges up (52 volts) and all seem fine under load (none below 7.9) 2 year old batteries. Water levels good. Upgraded MCOR to MCOR4 conversion kit New HD Solenoid installed Altrax 400 amp controller installed and tuned correctly to get 100% throttle 4awg wires on batteries. (stock wires to motor and F/R switch) Stock F/R switch Stock Series motor Correct Air pressure in tires HD springs on rear Tow settings correct and worn front end parts replaced Here is what I think I need to upgrade. PLEASE advise if I am either in "overkill" mode or not thinking this through correctly. Order HD F/R switch Order 4awg to motor and F/R switch Upgrade motor to a high speed/torque motor Also any suggestions on motor would be helpful too.

03-01-2015, 09:10 AM	#2
mrgolf Old Sky Soldier Join Date: Dec 2011 Location: Kentucky Posts: 3,881	Re: Help with 2001 Series DS build You may get a big improvement with the cable upgrade, and the f&r switch. You may not need the motor just yet. I would like to hear how much those changes do before you change the motor. In fact I think just the cables may make quite a difference. I'm trying to con you into doing those checks and letting us know the results.

03-03-2015, 06:14 AM	#4
DJBlade Gone Wild Join Date: Dec 2011 Location: Columbia, South Carolina Posts: 258	Re: Help with 2001 Series DS build Well this sucks. Cart just died. ALTRAX shows 7 blinking light,solenoid clicks, and goes nowhere. Could it be the F&R switch? It original and with the extra amps I feel that may be the culprit. Thankfully I have one ordered. One other thing....if I hold the pedal down while it isn't moving I get 4 red lights on controller....thermal detection. I'm guessing a buildup of excess heat since amperage won't pass through switch to motor?!? Any help or thoughts appreciated.

03-05-2015, 03:57 PM	#5
Golfdog Gone Wild Join Date: Dec 2010 Posts: 487	Re: Help with 2001 Series DS build As you have a Series Motor increasing Controller amps won't give more speed, you need to either swap motor for one wound for speed or increase the voltage thu the standard motor. a 36v motor would give you a nice improvement.
Golfdog Gone Wild Join Date: Dec 2010 Posts: 487

03-05-2015, 04:59 PM	#6
DJBlade Gone Wild Join Date: Dec 2011 Location: Columbia, South Carolina Posts: 258	Re: Help with 2001 Series DS build Well ain't this crazy! As I said before, the cart died on me and I have a F&R switch on the way.....which is good. I need one anyway. But something inside my pea brain told me to check, check, and recheck the battery cables. Well, I took it a step further and replaced them with new ones.....made new ones. Clean terminals, clean connections and VIOLA....cart runs again. Tell me it ain't that easy!!

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03-01-2015, 09:39 AM	#3
DJBlade Gone Wild Join Date: Dec 2011 Location: Columbia, South Carolina Posts: 258	Re: Help with 2001 Series DS build Will do. I am ordering the F/R switch and cables as we speak. Thanks!

03-05-2015, 05:48 PM	#7
wards75 Getting Wild Join Date: Oct 2012 Location: Eastern NC Posts: 141	Glad you got the cart up and running again. The other day, I changed out 2 ring connectors on the F&R switch and it didn't run afterwards. Was told by a forum member or 2 to check my wiring that something was crossed and it was but the funny thing is, I didn't unplug anything until after it wouldn't run...but it was a crossed wire on the micro switches...strange for sure.

03-09-2015, 04:00 PM	#8
DJBlade Gone Wild Join Date: Dec 2011 Location: Columbia, South Carolina Posts: 258	Re: Help with 2001 Series DS build OK, I need some advise on this one please. I got this cart at a deal knowing it didn't run. I figured I could fix it but it is whipping my butt. Here is what I have done and what the symptoms are. Cart will intermediately go forward fine and reverse fine. Ever so often it won't budge but the solenoid will click...just sits there. Slamming foot on accelerator and F&R back and forth and it takes off again and runs fine. 1. Upgraded MCOR to MCOR4 2. Installed HD F&R switch 3. 4 AWG cables nearly throughout ( yet to replace cables from F&R to motor and controller 4. New HD Solenoid 5. 400 Amp Alltrax Controller What could be causing the cart not to run but to have the solenoid click? I am at a loss. Maybe the new MCOR4 has failed? Any experts on a 2001 DS out there that can help would be greatly appreciated. I want to feel comfortable taking this cart out on hunts with me.

03-09-2015, 04:19 PM	#9
Sergio Gone Wild Join Date: Sep 2012 Location: Charlotte, NC Posts: 9,329	Re: Help with 2001 Series DS build The only thing I can think of it would be micro switch #3 (the 1/2 speed one) http://www.buggiesgonewild.com/attac..._with_mcor.jpg Just by-pass it to eliminate the possibility.

03-09-2015, 04:39 PM	#10
DJBlade Gone Wild Join Date: Dec 2011 Location: Columbia, South Carolina Posts: 258	Re: Help with 2001 Series DS build Well those are all new too. Should have mentioned that.

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