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Sakai SV544 - User Manual

Sakai SV544
32 pages
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SV544
Diagnostic
Information
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Summary

Safety and Operational Warnings

General Operating Safety

Covers machine movement, parking, chocks, and hazardous area safety precautions.

System Safety Precautions

Details safety measures for hydraulic systems, engine starting, and compartment inspections.

Engine Specifications

Engine Details

Covers model, type, displacement, speed, output, torque, and fuel consumption.

Lubrication and Fluid Specifications

Lists oil types, grease, fuel, DEF, and their applicable standards.

Component Capacities

Details capacities for engine oil pan, fuel tank, coolant, and other fluid reservoirs.

Hydraulic System Specifications

Propulsion Circuit Pressures

Details relief valve settings, case pressure, and drainage for the propulsion system.

Vibration Circuit Pressures

Specifies relief valve settings, case pressure, and drainage for the vibration system.

Steering and Brake Pressures

Covers brake release pressure and steering oil pressure specifications.

Filter System Components

Air and DEF Filtration

Identifies air cleaner and DEF tank filter assemblies and elements.

Hydraulic and Fuel Filtration

Covers hydraulic and fuel filter assemblies and their elements.

Engine Oil Filtration

Details the engine oil filter element.

Operator Console and Indicators

Control Layout and Functions

Identifies and describes console controls, switches, and levers.

Dashboard Displays and Indicators

Explains dashboard meters, warning lamps, and indicator lights.

Combination Meter and Connector

Indicator Descriptions

Lists and describes the various indicators on the combination meter.

Connector Pin Assignments

Details the pinout for the harness side connector.

Electrical Box Components

Control and Relay Units

Identifies ECO controller, relays, and fuses within the electrical box.

Connectors and Diagnostic Points

Highlights diagnostic and service tool connection points.

Fuse and Relay Assignments

Relay Functions

Lists and describes the functions of various relays (B-series, A-series).

Fuse and Spare Assignments

Covers fuse ratings and spare locations within the fuse box.

Battery and Starter System

Main Power Components

Identifies battery relay, starter relay, and main fuses for the power system.

Circuit Diagram Overview

Provides a schematic of the battery and starter circuit.

Troubleshooting and Diagnostics

Diagnostic Code System

Explains fault code messages and the diagnostic process.

Engine Diagnostic Manual Reference

Refers to a separate manual for detailed engine troubleshooting.

ECO Controller Diagnostics

LED Indicator Status

Describes normal and abnormal status indications by LED lights.

Error Code Interpretation

Details error codes, descriptions, and bypass actions for the ECO controller.

Troubleshooting: No Crank, No Start

Initial System Checks

Covers display, park brake, neutral, and battery voltage checks.

Starter and Relay Diagnosis

Details steps for checking the starter, relays, and fuses.

Fuse and Relay Locations

Starting System Fuses and Relays

Identifies locations of starter lockout, neutral safety, and park brake relays/fuses.

Main Electrical Components

Points out ECM fuse, battery relay, and starter relay locations.

Starting System Wiring Diagram

Power Supply and Control Circuits

Illustrates power flow from battery through key switch and relays to starter.

Switch and Relay Connections

Shows how neutral, park brake, and starter relays interact with switches.

Troubleshooting: Fuel System Issues

Engine Code and Fuel Availability

Guides through checking engine codes and fuel levels in the machine.

Fuel Delivery Path Checks

Details checks at filters and fuel pump for fuel presence.

Troubleshooting: Vehicle Not Driving

Drive System Checks

Covers unloader valve, parking brake, and drive cable issues.

Brake and Solenoid Diagnosis

Guides through brake switch, solenoid, and relay checks.

Brake System Wiring and Components

Brake Control Circuitry

Shows wiring for brake switches, solenoids, and relays.

Key Brake System Parts

Identifies brake switches, solenoids, and the brake release valve.

Propulsion Circuit Pressure Measurement and Adjustment

Pressure Measurement Procedure

Details steps for measuring propulsion circuit pressure.

Pressure Adjustment and Torque Specs

Explains how to adjust pressure and lists torque specifications.

Propulsion Motor Pressure Measurement

Measurement Setup and Procedure

Outlines steps for measuring propulsion motor pressure.

Flushing Relief Valve Setting

Specifies the standard value for the flushing relief valve.

Troubleshooting: Rabbit Mode Engagement

Solenoid and Fuse Checks

Guides through checking the drum speed change solenoid and fuse F6.

Speed Select Switch and Solenoid Function

Covers checks for the speed select switch and solenoid magnetization.

Travel Mode and Speed Control

Speed Range Selection

Explains the travel mode switch and available speed ranges.

Slope Operation Modes

Describes how slope operation is selected within travel modes.

Rabbit Speed Control Wiring

Solenoid and Switch Connections

Details wiring for rabbit speed solenoids and mode switches.

Speed Change Logic

Shows how speed change switch positions map to terminals.

Troubleshooting: Vibration System

Vibration Direction and Switch Checks

Covers issues with vibration in one direction or switch functionality.

ECO Controller and Solenoid Diagnostics

Guides through ECO controller and solenoid checks for vibration.

Vibrator Control Operation

Vibrator Switch Functions

Explains how the main vibrator switch controls amplitude and On/Off.

Vibration Selector Switch Usage

Details the function of the vibration selector switch on the F-N-R lever and panel.

ECO and Vibrator System Wiring

ECO Controller Connections

Details pin assignments and connections for the ECO controller.

Solenoid and Switch Wiring

Illustrates wiring for vibrate solenoids and associated switches.

Vibrator Circuit Pressure Measurement

Pressure Measurement Procedure

Outlines steps for measuring vibrator circuit pressure.

Relief Valve Inspection and Adjustment

Details inspection, cleaning, and replacement of the high pressure relief valve.

Vibrator Charge Circuit Pressure Measurement

Charge Circuit Measurement Procedure

Details steps for measuring vibrator charge circuit pressure.

Charge Relief Valve Adjustment

Explains adjustment of the charge relief valve and its setting.

Air Conditioning (AC) System

AC System Specifications and Safety

Lists AC capacity and important safety precautions for handling refrigerant.

AC Component Identification

Identifies key components of the AC system, including control panel and internal parts.

AC System Electrical Schematic

Circuit Breakers and Power Supply

Details circuit breakers and DC power inputs for the AC system.

Control and Component Wiring

Shows wiring for fan switch, thermostat, compressor, and motors.

Sakai SV544 Specifications

General IconGeneral
BrandSakai
ModelSV544
CategoryConstruction Equipment
LanguageEnglish

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