ez go dcs resistor super hot with no power

[termite40]

background- 99 dcs cart stretched, lifted, and big wheels and tires. Prev. issues with solenoid heating so replaced controller with 400 amp and also a heavy duty controller. Ran good. Last trip overloaded with seven adults for a long ride and killed the batteries, barely made it home. Charged for 12-14 hours and let sit for a day. Turned key and hit pedal and nothing. Checked solenoid and no clicking and not hot. However resistor on solenoid super hot. Stayed hot with no key turned on and no pedal depressed. Had to unhook battery. Any ideas, and my pack voltage is good.

[JohnnieB]

When the resistor is cool, reconnect battery without turning key on or pressing pedal. If the resistor gets hot, you probably have some shorted MOSFETs in the controller.

What 400A controller do you have? (Alltrax DCX-400 or something else)

[termite40]

Not sure of the controller make- cart is in VA and I'm now in PA. I did find out that it started as a Dcs but was converted to a pds. Has the mechanical FNR switch but has a pds programmable controller.

[JohnnieB]

The test I described will work on any controller.

Post pictures of controller when you get back to VA.

[termite40]

Trying to load pics

[JohnnieB]

That is more or less a stock PDS controller that someone has tinkered with to up the amp throughput from 300A to 400A.

By saying it is programmable, I suspect you are referring to the different plugs that can be inserted into the upper left 4-pin connector (J2) to select the four PDS modes. That means it and user selectable modes rather than being truly programmable.

In a nutshell, even with someone replacing the stock MOSFETs with higher capacity ones (or adding more in parallel), that controller is not designed to turn oversized tire or moving a cart with seven passengers, so I suspect it has finally failed.

Since whoever altered the cart from a DCS to a PDS apparently managed to get the wiring compatible with a PDS controller. I'd replace it with an Alltrax XCT-48500-PDS controller, which is truly user programmable with a laptop and USB cable.