• Connecting the KSI terminal on the controller to the 12V battery. It must be connected to the power pack.
• Not using the Potter-Brumfield relay to maintain high pedal protection - a safety feature.
• Putting more than 12V across the contactor coil. This will burn out the coil.
• Using smaller than 2/0 cable or battery cable and poor quality lugs. This will decrease acceleration and range due to the added resistance.
• Connecting the batteries incorrectly; typically, the lugs go on the outside of the battery terminal.
• Locating the first and last battery beside each other; this contributes to a potentially dangerous situation.
• Charging the battery with the DC/DC converter not isolated; this can damage the DC/DC converter.
• Connecting the high voltage side of the DC/DC converter to the 12 V side. This will damage the DC/DC converter immediately.
• No fuses in each circuit and no switch to turn the electrical component "on". This is potentially dangerous.
• Single color wiring - hard to distinguish circuits.
• Trying to charge a 120 V battery pack with an undersize charger (e.g. 108V).
• No gauges - how can you tell what's happening?
• Using the auxiliary shaft instead of drive shaft to the transmission. The drive shaft is the larger diameter.