[Al Skierkiewicz]

Xeno,
There is a good possilbity that your battery wiring is faulty. Check to see that all hardware is tight and all crimps are secure. Pull and tug on the wiring from the battery to breaker to PD. The 120 amp breaker may also be defective. With the robot on, try lightly tapping the red button, if the lights on the robot flicker, replace the breaker. You may also try tapping the body of the main breaker with a screwdriver handle to see if it is intermittant. We had a bad breaker in KOP this year that failed when tapped on the body. Double check your voltge readout on the DS, does it stay at 12 volts when you try things out? A small variation is normal when the robot is not running on the floor.
There are a few things that would point me to change the CIM motor. Although highly unlikely, there is a possibility that there is a defect in the CIM such that once the temperature starts to rise internally, the motor shorts. When you run it with no load, the temperature doesn't rise nearly as fast as when you you load it. To isolate, remover the breaker for that motor and run the robot. Does the condition reoccur? If not, that points to the motor or the motor wiring.
Finally, the resistance reading to chassis is fine if it is over 100,000 from any terminal on the PD with the battery disconnected. You can have a 40 meg ohm reading with someone touching the chassis.