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Old 08-09-2019, 11:48 AM   #1
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Default Sevcon 633T45319 Code 4

I saw a similar post to this one, but different controller number. Power up, I get 4 green flashes. I have replaced the solenoid and still get the 4 flashes. Per a Columbia troubleshooting code guide, if the solenoid is good and operating, it is either the controller or the motor...

Looking for further guidance: Here's the whole story.

Batteries were replaced before any try at moving the cart. Cart had been left sitting garaged and unattended since January. Batteries were 3 1/2 yrs old and no water above any of the plates. So, first thing was replace batteries, make sure charger is OK.

Then I try to drive it. It gave me a solid green light and moved about 30 yds but at a creeping speed of 3-5 mph. Then it stopped and gave me the 4 flashes code. Could not get it to move again. Replaced the solenoid and got the green light (whoopee, short lived). It was on jack stands, cart moved but at same slow speed, then stopped and again 4 flashes.

In all fairness to my laziness and lack of electrically checking out the solenoid, when the cart moved a little only once right after we installed new batteries it was easy to assume the solenoid, based on the guide for 4 flashes. I really think the original may be OK.

Any ideas would be greatly appreciated.
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Old 08-09-2019, 03:02 PM   #2
Gone Wild
Join Date: Apr 2015
Location: Pennsylvania
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Default Re: Sevcon 633T45319 Code 4

That code seems to point to either line contractor not closing or not opening. The typical process for controls like these to check for that stuff is as follows:

Did not close check: Command solenoid closed and read cap bank voltage and compare to key switch voltage (typically needs to be within a volt difference)

Weld Check: Command solenoid open and measure cap bank voltage, pulse the armature once and check again. There should be a voltage drop.

So that said an issue like this could be caused by, miswiring of the motor, open motor/bad brushes, bad precharge circuit/resistor, a resistance in the key wiring, diode drop in the key wiring, or legitimately bad solenoid.
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