Re: Sevcon Controller #633T45303 flashing a 4 code.
Contactor: with wires disconnected, the coil (small spades on side) should read about 52ohms. The posts on top should read infinite. When activated, should read about 0 ohms. To test the top posts and make sure they close, you could apply 24 volts to the side spade terminals for a few seconds while reading the top posts. It's important to note that on the unsealed contactors, if sitting for any time, have been known to get little spider nests built into them just where the contacts are under the cover.
Brushes. Best to pull the motor and check. I've attached the Columbia motor guide I wrote a year or two ago.
Controller. Only way would be to remove and send in for testing.
Also, I've seem sometimes one bad battery in the pack which under load drops to 4 volts or less and can cause all sorts of odd effects on the controller. Make sure you have load tested each individual battery.
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