Sakai SV544 Guide

SV544
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.

544

SV544
SV544 Operators Manual
Scan QR Code to View

SV544

SV544

SV544

SV544

SV544

ECU Fuse 5a
ECO
Controller
Controller Fuse
Pump Neutral
Holding Relay
Pump Neutral
Relay
Plus 1 Service Tool Connection
Diagnostic
Connector
Diode Unit
Air Conditioner Relay
SV544

SV544

Battery Relay
30a Fuse
SBF 65a and 75a
10a Fuse
Main Starter Relay
SV544

NOTE:
For full description and additional
troubleshooting, please see the engine
Diagnostic Manual.
SV544

SV544

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?
SV544

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
SV544

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
SV544
Black/White
Red/Green
White
Blue
Red/Blue
White/Red
White
Black/Yellow
Light Green
Light Green/White
White
Black/Yellow
Red

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.
SV544

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?
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
Pump Neutral Solenoid.
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?
SV544

12V Battery 12V Battery
Battery Relay
Battery
ACC Key Switch
F9 15a
Parking
Brake
Park
Brake Switch
SBF 65a
Foot
Brake Switch
Park Brake
Solenoid
Two Speed
Solenoid
Brake Release
Valve Neutral
Solenoid
Brake Switches
Park Brake
Solenoid
SV544
Pump Neutral
Solenoid
Brown/White
Blue/White