[Al Skierkiewicz]

A lot of info is passing through this thread and we do want you running for the weekend. If what follows doesn't get you help, ask for some of the teams to assist when you get to the Clash.
As to the first post, tripping the fuse while turning is a good indicator of the start current demands of the compressor. Although it is rated for 10 amps that is "run" current, start current is more than twice that amount and under certain conditions we have measured four times that amount. (For a very brief time during start.) When turning, currents are very high for the drive motors. Tank style steering (where no wheels turn but motion is accomplished by speed differences between the two sides) are the one of the highest current demand drives you can use. (Belt style tank being the worst.) As the battery tries to deliver power during these high demands, the terminal voltage can fall below the point at which the compressor continues running. So the effect is turn, compressor shutdown, compressor restart, turn, shutdown, restart, etc. Each restart of the compressor is accompanied by a high current pulse that heats up the fuse and failure is the result. Replace the fuse and continue beating up the spike and failure will result there as well. So that in a nutshell is the normal failure in this application. However, you may have a different problem altogether since you have replaced the spike and wiring multiple times. I have to ask if the location is very tight and other wiring had to be disturbed to make the changes. There is a distinct possibility that 1) the spike was rotated when replaced, 2) the wiring to the spike was exchanged with another component near it, (another relay or controller), 3) the compressor has shorted, or 4)in replacing the fuse and/or spike, the wiring from the pressure switch was broken and your software is no longer receiving a command to start the compressor. High on my list are #4 and #1. A simple check of the switch wiring and connection back to RC is very easy to do. Checking on the orientation of the spike is also very easy to do. My rule of thumb when troulbeshooting a working device is "go where the last person was" which will be the spike replacement.