Re: DCS solenoid no click hot resistor
Fully charged batteries ought to be 38.2V or higher.
Solenoid not clicking is why the resistor is getting extremely hot. Contacts not closing, so the motor is trying to draw amps through the 250Ω resistor.
Apparently, B+ is getting to the solenoid coil since the controller is trying to pass amps and the solenoid's small terminal with red and yellow wires on it is in parallel with Pin-6 on the controller, which powers up the controller. Looks like the pedal switch is bad, if not the controller might be bad. (But that would make two controllers with same failure, so I suspect it is the pedal switch.)
BTW: Better take a closer look at the ITS voltages.
Pin-2 ought to be from 14V to 16V. You have 12V, so it is out of specs.
Pin-1 ought to be 0.45V to 0.53V when pedal is pushed just far enough to make solenoid click and from 1.50V to 1.75V with pedal on floor.
DCS ITS testing from service manual attached and a schematic.
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