In MFL's explanation I can see the heavy braking. If he has chafing in of the insulation and the inside of the axle tube is rusty he has an intermittent high resistance short. So when he applies the brakes some current goes to the magnet and some current goes into the rusty axle tube causing weak brakes. Since the brakes are weak he cranks up the gain on the controller to compensate. Next road bump and the wire moves and is no longer shorted to the tub. Now when he touches the brakes he gets the full voltage at the brakes locking them up.