My Msuper3s+ has failed again (3rd time).
The first failure was documented here: http://forum.electricunicycle.org/topic/7595-gotway-msuper-v3s-84v-1300wh-failed-loose-axle-nut/?tab=comments#comment-101925
The second failure was documented here: http://forum.electricunicycle.org/topic/8082-my-new-gotway-msuper-v3s-84v-1300wh-failed-again/?tab=comments#comment-113358
This time I was traveling about 15mph on level concrete and the wheel suddenly quit and fell forward crashing the corners of the case. When I pushed the button to turn it back on, I heard the audible signal for Hall Sensor Failure (two fast beeps following by a 1/2 second pause, repeating). No balancing function.
When I opened the side covers I found a signal cable was pinched (red circle below) by the side cover due to improper routing. This cable has no slack from above or to the connector. This cable contains red, black, and white wires that connect on the top forward connector of the main board. I doubt this is related to the failure, because it isn't a hall sensor signal, and wiggling it doesn't stop the beeping. What is the function of the top forward connector of the main board?
I saw a very small flexing movement on the right end of the axle as I rotated the tire back and forth. I can hear various abnormal noises from inside the motor when I rotate the wheel. Sometimes it sounds like broken pieces and grinding or scraping. I can feel slight mechanical hysteresis in the feedback when I change direction of rotating, like some small parts are flexing inside. Maybe this makes sense to someone?
This case and side panels are totaled (split open, stripped threads, lamp dislodged, etc.). I really want to understand the cause(s) of these failures so I can change something to prevent recurrence.