Toyota 8FGU25 Forklift OEM Service & Repair Manual
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SAS/OPS
Page Page
GENERAL .............................. 16-2
SAS FUNCTION .................... 16-4
COMPONENTS ....................... 16-4
PRECAUTIONS FOR
REPAIR .............................. 16-10
SAS/OPS CONTROLLER
REMOVAL·INSTALLATION...16-13
YAW RATE SENSOR
REMOVAL·INSTALLATION...16-14
TIRE ANGLE SENSOR (OPT)
REMOVAL·INSTALLATION...16-15
SWING LOCK CYLINDER
REMOVAL·INSTALLATION...16-17
STEERING KNOB POSITION
CORRECTING VALVE (OPT)
REMOVAL·INSTALLATION...16-19
TILT ANGLE SENSOR
REMOVAL·INSTALLATION...16-20
LOAD SENSOR
REMOVAL·INSTALLATION...16-21
SPEED SENSOR
REMOVAL·INSTALLATION...16-22
FORK HEIGHT SWITCH
REMOVAL·INSTALLATION...16-23
FUNCTIONAL PARTS ............ 16-24
OPS FUNCTIONS ............... 16-25
GENERAL ............................ 16-25
CONTROL SPECIFICATION... 16-25
MATCHING .......................... 16-26
GENERAL ............................ 16-26
BEFORE STARTING
MATCHING ........................ 16-27
OPTION SET ....................... 16-31
DIAGNOSIS MEMORY ........ 16-33
REAR WHEEL SWING
CONTROL CHECK............ 16-34
SAS/OPS PLUG-IN
ANALYZER ........................ 16-35
16-2 16-2
GENERAL
SAS (System of Active Stability) /OPS (Operator Presence Sensing) system configuration
Sensors are installed at each point of the vehicle to detect the vehicle movement and send signals to the controllers.
These signals are controlled by the controllers, and sent to each actuator to be operated.
(1)
S T K
Control
Control
S
T
K
O
S,T
K,O
Actuator Sensor
O
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
(12)
(13)
(14)
Fork height switch
Swing lock cylinder
(Single tire only
Tilt control valve
Lift lock valve
Knob position correcting
valve
Error lamp
Error code display
S :Rear wheel swing control
T :Mast tilting control
K :Steering knob position control (OPT)
O:OPS control
Forward interrupt relay
Backward interrupt relay
Unload valve
Lift lock valve
Backward tilt lock valve
(Standard lever vehicle only)
OPS lamp
Buzzer*
Tilt control valve
Tilt angle sensor
Forward tilt switch
Backward tilt switch
Lower switch
Load sensor
Fork automatic
leveling switch
Speed sensor
Steering wheel
angle sensor
Tire angle sensor
Yaw rate sensor
(Single tire only
Seat switch
Forward switch
Backward switch
Controller
Input
Output
S,T
K,O
S,T
K,O
Plug-in anallyzer (SST)
Multifunction display DX
(OPT) (Bilt-in analyzer)
Output
*: The OPS buzzer sounds only on the
export model except "WITHOUT OPS
BUZZER" specification.
SAS / OPSS
Section 16
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*1 For the mini lever/joystick vehicles, (3) (4) and (5) switches are the lever angle sensors.
No. Name No. Name
(1) Fork height switch (15) Swing lock cylinder
(2) Tilt angle sensor (16) Tilt control valve
(3) Forward tilt switch *1 (17) Lift lock valve
(4) Backward tilt switch *1 (18) Knob position correction valve (OPT)
(5) Lower lift switch *1 (19) Forward interrupt relay
(6) Load sensor (20) Reverse interrupt relay
(7) Fork automatic leveling switch (21) Unload valve
(8) Speed sensor (22) Backward tilt lock valve
(9) Steering wheel angle sensor (OPT) (23) Buzzer (Export model)
(10) Tire angle sensor (OPT) (24) OPS lamp
(11) Yaw rate sensor (25) Error lamp, Error code display
(12) Seat switch (26) Multi-function display
(13) Forward switch (27) Plug-in analyzer
(14) Reverse switch (28) SAS/OPS controller
(3)(4)(5)(6)
(16)(17)(21)(22)
(9)
(13)
(14)
(19)
(20)
(27)
(8)
(2)
(23)
(28)
(18) (11)
(15) (10)
(1)
(7)
(26)
(24)(25)
(12)
SAS / OPSS
Section 16
16-4
SAS FUNCTION
COMPONENTS
Controller Yaw Rate Sensor (except Cu1)
Yaw Rate Sensor (Cu 1 ton series)
SAS / OPSS
Section 16
16-5
Tire Angle Sensor (OPT)
Swing Lock Cylinder (except Cu1) Swing Lock Cylinder (Cu1 ton series)
SAS / OPSS
Section 16
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Toyota 8FGU25 Forklift OEM Service & Repair Manual
The Toyota 8FGU25 Forklift OEM Service & Repair Manual is a factory-issued guide built for hands-on pros and savvy DIYers keeping their lift trucks in top shape. Whether you're dealing with the 4Y-E or 1DZ-II engine, this manual walks you through essential service procedures without overcomplicating things.
Inside, you'll find step-by-step instructions for engine overhauls, transmission repairs (including Pn and Cu series), mast and hydraulic cylinder maintenance, and brake system servicing. It also includes forklift-specific components like joystick (mini lever) diagnostics, SAS/OPS safety systems, and material handling assemblies. The manual's got a clear breakdown of the axle, steering, and propeller shaft systems, too.
Content overview:
- General specifications and service guidelines
- Chassis and engine diagnostics and repairs
- 4Y-E engine overhaul and LPG system servicing
- 1DZ-II engine disassembly and reassembly
- Transmission repairs for Pn and Cu series forklifts
- Propeller shaft and differential servicing procedures
- Front and rear axle maintenance
- Steering system diagnostics and repairs
- Brake system inspection and servicing
- Forklift body structure service procedures
- Material handling system component servicing
- Mast and hydraulic cylinder maintenance
- Oil pump and oil control valve repair
- Joystick (mini lever) function checks and service
- SAS / OPS safety system overview and servicing
- Service standards and reference list (SSTLIST)
- Optional multifunction display (DX) diagnostics
- Electrical system troubleshooting (all models)
- Electrical diagnostics for Cu1 ton series
- Complete wiring diagrams
- Factory service bulletins and updates
If you're wrenching on a fleet or just keeping a single 8FGU25 running strong, this manual makes the job easier. It's a solid fit for both forklift techs and garage tinkerers who want OEM-level precision at their fingertips.
Printable: Yes
Language: English
Compatibility: Pretty much any electronic device, incl. PC & Mac computers, Android and Apple smartphones & tablet, etc.
Requirements: Adobe Reader (free)
