Sakai 544 Guide

544
Diagnostic
Information

Please See Operators and Service
Manual for additional
information.
ALL Work Must be performed by
a factory trained technician to
prevent injury. This manual is not
intended to replace the service
manual but to assist with
additional information.

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SV544 Operators Manual
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NOTE:
For full description and additional
troubleshooting, please see the engine
Diagnostic Manual.
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No Crank, No Start
Yes, Is machine in “Neutral” drive position
Yes, Is the park brake “ON”? No, Shift drive lever to “Neutral”. Does engine crank?
Yes, End diagnosis. No, Is the park brake “ON”?
No, Engage Park Brake.
Does engine crank?
Does the display come on when key is turned on?
No, Test Battery, is there 24v present?
No, Replace or Charge
Battery as needed.
Yes, Does Battery
Relay, engage when
key switch is turned
to “ON” position?
No, Is there 24V power from
key switch (Black/Red stripe)
at Battery Relay?.
ECM Fuse 5A
Yes, Repair Connection or Replace
Battery Relay as needed.
No, Repair
Wiring from
Key Switch.
Yes, Check connections
and replace Battery
Relay as needed.
Yes, End diagnosis.
No, Is there power at Terminal 50
Black/White wire on the Starter when
turned to “Crank” position?
No, Engage Park Brake.
Does engine crank?
Yes, End diagnosis.
Yes, Repair connections or replace starter as needed.
No, Check continuity across the Park Brake switch and Neutral Switch? Does the switches test good?
No, Repair or
replace as needed.
Yes, Test for power across relays for Starter, Starter Interlock, park brake switch and Neutral Switch? Do the switches test good?
No, Repair or
replace as needed.
Yes, Check fuse for ECM 5a, Interlock 15a, and Starter Relay 20a. No, Replace fuses as needed or ECM
needs to be tested.
Yes, Is there power at
Terminal 50 Black/White
wire on the Starter when
turned to “Crank” position?

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Starter
Lockout
relay
Starter
Lockout
Fuse 20a
Neutral, Park
Brake Switch Fuse
15a
Neutral
Safety
relay
Park
Brake
relay
Battery
relay
ECM
Fuse 5a
Neutral
Switch
Starter
relay
30a ECU
Fuse

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12V Battery 12V Battery
Battery Relay
Battery
Key Switch
ACC
Fuse 5a
ECM
ECM
Neutral Relay
Park Brake Relay
Fuse 15a
Interlock
Crank
Fuse 20a Starter
Neutral Switch
Brake Switch
Starter
Relay
Starter Lock
Out Relay
SBF 65a
Fuse 30a
Battery + Pins
1 25 26 27 28
Ground Pins
49 50 51 52 73

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Crank, No Start
Are there any Engine Codes present?
Yes, Please consult local Cummins Dealer
No, Is there fuel in the machine?
No, Add Fuel and Prime using hand pump. Yes, Is there fuel present at filters?
No, Replace filters as needed or remove
fuel restriction, repair as needed.
Yes, There fuel present at Fuel Pump ?
No, Replace filters as needed or remove
fuel restriction, repair as needed.
Yes, Please consult your local
Cummins Dealer.

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Will not Drive
Yes, Disengage park brake.
No, Inspect Drive Cable. Is cable still connected?
Yes, Test Foot Brake Switch. Is there voltage present at the switch?
No, Re-Install Cable and test.
No, Check Fuse 9 (15a) and wiring and connections
from Fuse and repair as needed or replace blown fuse.
Yes, Test Foot Brake Switch. Is there voltage on both terminals at rest?
No, Check Pump Neutral Relay for voltage on
Blue/Yellow Wire when Park Brake Switch in
“OFF” Position. Is there voltage present?
Yes, Repair or Replace
switch as needed.
Pump Neutral Relay No, Repair or Replace Park Brake switch as needed.
Yes, Is there power at Park Brake Solenoid
when switch is in “OFF” Position?
No, Test Neutral Relay.
Does power leave
relay to supply Park
Brake Solenoid?
Yes, Use Brake Release valve to
release brakes. Does machine Drive?
No, Inspect Drive Pump and
Repair or Replace as needed.
Yes, Inspect Brake
Solenoid and repair or
replace as needed.
Drive Cable
Park Brake
Solenoid
Two Speed
Front Solenoid
Brake Release
Hand Pump
Brake Switch and Pedal
Neutral
Solenoid
Is the Unloader valve open? Will not drive with valve open
Yes, Close valve to drive. No, Is the Parking brake engaged?

2
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12V Battery 12V Battery
Battery Relay
Battery
ACC
Pump Neutral
Relay
Key Switch
Fuse 15a
Interlock
Park
Brake Switch
SBF 65a
44
Pump Neutral
Holding Relay
Foot
Brake Switch
21
Park Brake
Solenoid
Two Speed
Solenoid
Brake Release
Valve Neutral
Solenoid
Brake Switches
Park Brake
Solenoid

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Will not go into Rabbit Mode
Is there power at the Drum Speed Change solenoid?
Yes, Remove Coil from valve. Activate Rabbit mode. Does coil magnetize?
Yes, Test Solenoid valve and
Charge Pressure.
No, Replace or Repair coil as needed
No, Inspect F6 (15a). Is there power across the fuse?
Yes, Is there power on the Blue Wire at
the Speed Select Switch?
No, Replace Fuse or repair
connections at fuse terminal.
No, Repair wire from F6 to Speed Select Switch.
Yes, Is there power at Speed Selector Switch
on Blue/White Stripe and Brown/Black
Stripe when turned to Rabbit position?
No, Repair or replace defective switch or wire connections.Yes, Repair wiring from Speed Selector Switch to Solenoids.
NOTE: If Rabbit and Turtle both work,
Traction control is working properly.

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Travel Mode
Relay
Speed Change
F6 15a
Speed
Change
Solenoid
Axle
Two Speed
Drum Solenoid
Axle Drive Motor

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12V Battery 12V Battery
Battery Relay
Battery
ACC Key Switch
SBF 65a
SBF 75a
1
4
2
6
3
5
F6 15a
Rabbit Speed
Solenoid Axle
Rabbit Speed
Solenoid Drum
5
4
21
3
Travel Mode
Relay (A3)
Travel Mode Switch
1
2
3

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Will not Vibrate
No, Are the Vibrate Switches in correct position? No, See Next Page Or Ops Manual for More Info.
No, Does the machine Vibrate using continues Vibrate Switch on dash?
Does Machine Vibrate in one travel direction but not the other? Yes, Open Circuit in harness to Lever Switch
No, Is there a Green Diagnostic Led on the ECO controller?
Yes, Short in harness to Lever Switch
No, Watch for Reb Blink Codes See TS Code List
Yes, Remove Motor and check to see if Shaft is broken?
ECO Controller
Yes, Repair broken shaft to Vibrate Motor.
ECO/Full
Speed
relay
ECO/Full
Speed
Fuse 20a
Yes, Repair Broken Shaft Parts No, Inspect power across F16 20a. Is the fuse good?
Yes, Is there power at the Vibrate Mode Switch?
Red/Blue Stripe
No, Replace defective fuse or repair
connection.
No, Defective ECO/Full Speed relay or repair wire from
ECO/Full Speed Relay.
Yes, Is there power at the Vibrate
H/L Switch? Yellow Wire
No, Repair wiring from Mode Switch or Mode Switch
Yes, Is there power at Pin 9
High and Pin 10 Low of ECO
Controller? Yes, Is there Power at the High/Low Vibrate Solenoids?
No, Repair wiring from Switch or Repair Switch. No, Repair Wiring or ECO Controller Yes, Test Valves Hydraulic Pump and Motors
ECO
Controller
Fuse 15a

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