Need a little help with diagnosis - 48v '01 PDPlus Regen 2

jakebdb56

Well here's what the cart has:

6 8 volt Trojan batteries in good condition
AllTrax DCX 400 PD Plus Regen 2 Controller
Upgraded MZJ-200D Contactor with 1amp diode and 470ohm resistor
New 4ga Battery Cable Kit
Stock high torque club car motor.

Here's what happened in April:

We drove the cart around all day at a track event. Prior to this I didn't know that someone had put a 6volt battery in place of an 8volt, so the pack voltage was within range, but not "right". At the end of the night, we knew the cart was getting low on juice. Coming to the staging lanes the cart stopped running completely, and I smelt a little burning smell. Nothing was obviously on fire or smoking. The next day I looked at everything and couldn't find the issue. I called AllTrax support and we figured out that the 10ohm resistor that receives pack voltage had actually burnt up. They sent me a new adapter.

I realized during the diagnosis that the pack had a 6v battery in it, so I went and got a new 8v the next day and installed it.

I put the new adapter on, key on, forward switch on, solenoid opens like it's supposed to and the green light is on on the controller. As soon as the throttle pedal was depressed that resistor would blow. I soldered another resistor onto the board and the same thing. I double and triple checked the wiring on everything and determined that the wiring was correct. I didn't change a single thing from when the cart was running for a year to the time it was dead and diagnosing this issue.

The cart charges just fine, and the pack voltages are correct after the charge and the batteries definitely have juice in them. The solenoid works properly, and all points have the right voltage per talking with AllTrax and using a multimeter to test everything.

That being said, what could the issue possibly be?

Bad motor? (I went ahead and got a plumquick upgraded unit that needs to go in)
Bad controller?
Bad pedal? (the potentiometer is clean and reads out all correct)

No blown fuses either.

Any help or insight would be great. I screwed up last night and put the blue and white jumpers on backwards which indeed fried my controller. I know I need to replace it now, but I would like to make sure that I'm not missing something before I go and put another 400 dollar controller in there and keep blowing the resistor on the adapter.

Sorry for the novel, just trying to get this thing figured out. Thanks in advance...

BGW

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Stevegrmich

jakebdb56

lol right!

I've heard from a handful of people that the motor could just be totally screwed up and that would make it blow that resistor, others say it's just the controller being messed up. Either route if the low voltage scenario before resulted in controller failure, I'll have a new controller on the way soon and I have all 8v batteries.