Toyota 8FGU25 Forklift OEM Service & Repair Manual
What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
16-1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
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
16-3
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
E
*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
16-6 16-6
Steering Knob Position Correcting Valve (OPT)
Fork Height Switch (V Mast)
4507
5803
4507-285
Refer to
4302-01
Refer to
6705-01
AU
CA
55A 55
AZ
JP
53
AD
KL
BJ
Refer to
4503-01
CD
AS
CD
AS
55A
AT
CD
AX
CD
LJ
LJ
BJ
BZ
81
MP
MM
BJ
79
80
81
MR
CH
MR
CH
KP
KP
MN
GD
MN
GD
MM
Steering knob
position correcting
valve
5803-172
BY
10
BP
BX
64
AT
AV
AU
AV
AP
33
AS
CY
63
AR
62
AO
10
SAS / OPSS
Section 16
16-7
Fork Height Switch (FV Mast)
Fork Height Switch (FSV Mast)
5803
5803
5803-174
DA
62
AS
64
65
AZ
BC
BE
AR
AU
AV
AP
AO
AV
AT
33
BV
CZ
10
BY
BX
AW
10
5803-173
BY
BX
AW
10
DA
62
AS
64
65
AZ
BC
BE
AR
AU
AV
AP
AO
AV
AT
33
BV
CZ
10
SAS / OPSS
Section 16
16-8
Fork Height Switch (QFV Mast)
Tilt angle sensor (except Cu1) Tilt angle sensor (Cu1 ton series)
SAS / OPSS
Section 16
16-9
Load Sensor
Speed Sensor
5803
5803
5803-175
35
BK
BJ
C25(YELLOW FREIGHT)
SAS / OPSS
Section 16
16-10 16-10
PRECAUTIONS FOR REPAIR
Fully understand the functions of SAS/OPS before repairing it.
1. Preparation for repair
(1) When washing the vehicle, care should be taken not to
splash water directly to the electrical components.
Do not perform high pressure washing for the controller,
tilt angle sensor, yaw rate sensor, fork height switch, horn
button, meters, switches on the instrument panel and
electrical components and parts in the engine
compartment.
(2) Remove contamination and/or water from respective
sections.
(3) Transport the controllers in a packed state with cushions, and keep it packed until installation. Never
transport it in an exposed state. Also, do not apply mechanical shock on the controllers by dropping or
crashing them.
(4) Part number for a controller varies by the vehicle specifications. Check the correct part number in advance.
(5) If a repair work requires matching, always park the vehicle on a flat place.
(6) Arrange for necessary tools and measuring instrument (such as a plug-in analyzer (SST 09240-26600-71)
and TOYOTA electrical tester (SST 09082-76002-71 (SST 09082-00050)), etc.).
2. During repair
(1) Never use an impact wrench for removing and installing controllers and sensors.
(2) Do not turn the ignition key switch ON or OFF more than necessary when the sensor wiring is
disconnected. Turning the ignition key switch ON in this state causes an error and an error code will be
stored in the controller. The error code is not erasable and a maximum of ten errors will be stored. If 11 or
more error codes are stored, the oldest error code will be sequentially erased.
(3) When turning the solenoid (for lock cylinder, knob position correction valve (OPT)) ON during an “Active
Test” of the analyzer, do not keep it ON for more than one (1) minute. Since SAS/OPS functions are forcibly
suspended during an active test, use caution when performing the running test carefully at a low speed.
(4) SAS/OPS functions are suspended during matching. Do not operate the vehicle in this state.
(5) Do not turn the ignition key switch ON with one side (RH or LH) of a vehicle jacked up. It is very dangerous
to turn the ignition key switch ON in this state as it releases the swing lock and the vehicle becomes
suddenly tilted.
(6) If a vehicle is in tilted condition because of the repair of a flattened tire or other reasons, keep the ignition
key switch turned ON throughout from the start of jacking up, tire replacement and lowering to the ground.
(7) When the hydraulic piping is disconnected, apply cover to the fitting and hose to prevent the dirt from
entering.
(8) If the oil control valve for manual lowering is loosened, tighten it to a prescribed torque.
(9) Tighten respective set bolts to a prescribed toque.
(10) Respective sensors require no adjustment during installation. Make initialization during matching.
(11) To disconnect a connector, do not pull it by the harness.
(12) When inspecting the harness, carefully operate so as not to damage connector terminals.
(13) The swing lock cylinder must not be disassembled. If disassembled, air enters to make it not reusable.
(14) Do not apply strong impacts to the frame and head guard to prevent the yaw rate sensor from being
damaged.
(15) The meanings of high and low fork heights in the troubleshooting section are as follows:
Low fork height: From the lowermost position to immediately before actuation of the fork height switch
High fork height: Height above the position where the fork height switch is actuated
SAS / OPSS
Section 16
You're Reading a Preview
What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$39.99
Viewed 96 Times Today
Secure transaction
What's Included?
Lifetime Access
Fast Download Speeds
Offline Viewing
Access Contents & Bookmarks
Full Search Facility
Print one or all pages of your manual
$39.99
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)
