[trent_julie]

I've been watching this thread for a little now, and whilst i don't claim to be an expert on any type of mount, I do have an electronics background. I would be heading straight for that cable, I've seen many high tech pieces of kit come undone because of a simple cable. Noting that this may not fix the problem immediately, it will definitely prevent this cable becoming a problem in the very near future.

I can't emphasise enough to replace that dodgy connection, if the connections touch yes, you may read voltage with a multimeter on the connection, but this may account for bugger all in reality due to a thing called impedance (its caught many a technician unstuck) that little tang is what assists in overcoming this thing called impedance

As for the hand controller, without schematics I can't tell, but for the hand controller to get hot I'm thinking the motor driver side of things (it doesnt make sense to me that driver FET's or tranies be in the hand controoler though), there maybe a Watt of energy or more there to get the hand controller warm, far more power than is required by a standard micro-controller circuit.

One thing that concerns me (without electronic diagrams once more) is that the unit may have had reverse polarity applied to it, Ive seen it many a time where these diodes are not included for the mere fact that the designed connections are not intended to be altered eg a mobile phone battery will only work when placed in the mobile correctly, so why does it need reverse polarity protection?

In my experience electronic components don't always display a visible defect, test equipment such as a Oscilloscope are required to chase out the faults due to data passing, pwm waveforms etc

(Thats my best effort at electronics in English without getting into long winded explanations)

Heres the good news,

A TV Dr is a very adaptable being, in lieu of having a telescope mount electronics specialist readily at hand, Even better if you know of someone with a fair bit of electronics experience.
It may only cost you a six pack for labor and parts (thats my charge if I get it things going again)

Good luck with the mount, Truly, I can imagine the amount of angst this is causing, I eagerly await the result of the fault