[EricH]

Originally Posted by HarryScheiner

For all the gear ratio/mechanical questions:
We took a fresh battery and placed the wires from the motor DIRECTLY to the battery terminals. The motor spins and the entire mechanism works perfectly. I do not think the gear ratio or motor itself are the problem. We can do this again and again and it works, so we have not burnt out the motor or anything like that.

Umm... a 40 A breaker will let a lot less current through than the 120A main breaker, which can be tripped by the battery. That's a lot of current! That's also a bit of power available that you can't use.

It's probably not the motor. Likewise, it's probably not the Jag, unless it's burned out. We'll assume that that is not the case (for now), so let's continue up the system.

Code: Probably not, unless it's a Victor/Jag switch. We'll assume it isn't, for now.

That puts it in the gearing or the wiring/electronics.

Gearing: I'm asking because it takes more power to turn a lower ratio. If you gear the conveyor for speeds much faster than the motor, you'll notice this quickly. So it takes more current, which you now can't get. However, it sounds like your breakers aren't tripping. Probably not the gearing.

Check your wiring in that circuit. You might have loose connections, which limit the flow of current. I remember troubleshooting a robot that was having trouble driving. The problem was traced to a loose wire in one of the drive slots (or was it a loose breaker? Doesn't matter, I guess).