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Stalled motors
The first symtom you encounter if your robot is geared too high is that the 30 amp breakers will intermittently kick out. The drill motors draw LOTS OF CURRENT, like 100 amps or so, when stalled. You will not stall the drill motor longer than a second or two before the breakers trip. When you are geared "bordering on too high," the motors will run very hot and smell like they are burning up which, come to think of it, they are.
Our 2001 robot with tank drive and gear change is geared about as high as will work reliably in high gear under non-pushing and non-climbing conditions. In low gear, even with very good traction, it will slip rather than tripping breakers or stalling motors. We can run in low gear continuously for hours without the motors getting too hot. With the motors lightly loaded, the little fans inside do their job very well.
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Team 45, TechnoKats, 1996-2002
Team 1062, The Storm, 2003
Team 233, "The Pink Team," 2004-present
The views I express here are mine, and mine alone, not those of my team, FIRST, or my previous teams.
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