16-630

16 SAS/OPS
16.1 GENERAL.................................................................................................................................................................. 630
16.2 SAS FUNCTION...................................................................................................................................................... 634
16.3 OPS FUNCTIONS.................................................................................................................................................... 655

16.1 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 control-
lers. These signals are controlled by the controllers, and sent to each actuator to be operated.
 16-631

Control Con
Sensor Actuator
S T K O -trol
Swing lock cylinder
(1) Fork height switch S
(Single tire only)
Tilt control valve
(2) Tilt angle sensor
Tilt electric proportional
T
valve *2
(3) Tilt lever switch *1 Lift lock valve
Knob position correcting
(4) Tilt lever angle sensor *2 valve *4
Tilt control valve
Lift lock valve
(5) Lift lever switch *1
Unload valve
Tilt backward lock
(6) Lift lever angle sensor *2 Output valve *1
Lift electric proportional
O valve *2
(7) Load sensor Tilt electric proportional
valve *2
Automatic fork leveling Attachment 1 electric
(8)
control switch proportional valve *2
Controller
Input Attachment 2 electric
(9) Yaw rate sensor *3 proportional vavle *2
OPS indicator
(10) Vehicle speed sensor OPS buzzer *6
S,T Error lamp
Steering wheel angle K,O Error code display
(11)
sensor *4

(12) Tire angle sensor *4 MULTI-FUNCTION 16

Output S,T display
(13) Seat switch K,O (OPT)
(Built-in analyzer)
(14) Foward switch S:Rear wheel swing control
T:Mast tilting control
(15) Reverse switch K:Steering knob position control
O:OPS control
Attachment 1 lever angle
(16)
sensor *2
Attachment 2 lever angle
(17)
sensor *2

(18) Parking brake switch *5

*1:Without “MINI LEVER” option (STD)

*2:With “MINI LEVER” option (E45A)
*3:Only single tire models
*4:With “SYNCHRONIZED STEERING” option (E72A)
*5:Only models with “MULTIFUNCTION DISPLAY DX” option (L26B),
or models with “EEC. SPEC.” option (A10A),
or models with “EZ PEDAL” option (E43A).
*6:Only models with “MULTHFUNCTION DISPLAY DX” option (L26B),
or models with “EEC. SPEC.” option (A10A),
or models with “EXPORT SPEC.” option (E43A)
except “WITHOUT OPS BUZZER” option (K25N).
16-632

17
8

4, 6, 8, 19,
20, 21, 22
30
1
11, 19, 20
23
2, 31
10
9

18, 34
7, 14, 15,
32, 33 3, 5, 7, 16, 24, 25,
13 18 14, 16, 27, 28, 29
24, 25, 26
12

No. Name No. Name

1 Height switch 18 Seat switch
2 Tilt angle sensor 19 Forward switch
3 Tilt lever switch *1 20 Reverse switch
4 Tilt lever angle sensor *2 21 Attachment 1 lever angle sencer *2
5 Lift lever switch *1 22 Attachment 2 lever angle sencer *2
6 Lift lever angle sensor *2 23 Parking brake switch *3
7 Load sensor 24 Lift lock valve
8 Autmatic fork leveling control switch 25 Unload valve
9 Yaw rate sencor *3 26 Tilt backward lock valve *1
10 Vehicle speed sencer 27 Lift electric proportional valve *2
11 Steering wheel angle sencer *4 28 Attachment 1 electric proportional valve *2
12 Tire angle sencer *4 29 Attachment 2 electric proportional valve *2
13 Swing lock cylinder *3 30 Combination meter
14 Tilt control valve 31 OPS buzzer *4
15 Tilt electric proportional valve *2 32 Forward interrupt relay
16 Lift lock valve 33 Reverse interrupt relay
17 Knob positin correcting valve *4 34 SAS/OPS controller
*1:Without "MIN ILEVER" option(STD).
*2:With"MINI LEVER" option(E45A).
*3:Only single tire models.
 16-633

*4:With "SYNCHRONIZED STEERING" option(E72A).

*5:Only models with "MULTHFUNCTION DISPLAY DX" option(L26B),or models with "EEC. SPEC." op-
tion(A10A), or models with "EZ PEDAL" option(E43A).
*6:Only models with "MULTHFUNCTION DISPLAY DX" optiion(L26B), or models with "EEC. SPEC." op-
tion(A10A), or models with "EXPORT SPEC." option(A10A) . Except "WITHOUT OPS BUZZER" option(K25N).

16
16-634

16.2 SAS FUNCTION

16.2.1 COMPONENTS
Controller

(MINI LEVER)
AE
AP BZ
AB
18
BS

17
BV

BW
BS
13

AA
AD
17

BT

CO

AA
AO

1910-061
 16-635

Swing lock cylinder

GV

EH
16

BR
20A[FR]
20A

CL
EF
NA 20A
63[FR]

63[RR]

CL

EJ
EJ
GB[FR]
GB[RR]

4301-307B
16

Speed sensor

EN
AA

BR
31

5803-601
16-636

Fork height sensor (V)

10

CY

62

AS 10
AV
64
AP BY
AO
33

AT
AU
AV
BP

AR BX

63

5803-602

Fork height sensor (FV)

10

DA BC

65

AZ BE

10
AR

AV
AU AO
64
AP
AV

AT
AW
33

BV
CC
AS

BY

BX
CZ

DP 62

5803-604
 16-637

Fork height sensor (FSV)

10

BA BB 65
BB
BC

10

BE

AR

AZ AS AT
CC 64 33
AV AU BV
AW

DP AO
BY
AY
BX AP CZ
AV

62

5803-603
16

Pressuer sensor

35

5803-605
16-638

Tilt sensor

ED

11

36

HU

VK

KV

5803-606A

Yaw rate sensor

47

EH

(SPL DOUBLE, STD DOUBLE)

EH

AM

5803-607
 16-639

16.2.2 PRECAUTIONS FOR REPAIR

Fully understand the functions of SAS/OPS before repairing it.

NOTICE
Always disconnect the battery terminal before the inspection or servicing of electrical parts.

Step 1 Preparation for repair

• 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
16
switch, horn button, meters, switches on the instrument panel and electrical components and parts in the
engine compartment.
• Remove contamination and/or water from respective sections.
• 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.
• Part number for a controller varies by the vehicle specifications. Check the correct part number in ad‐
vance.
• If a repair work requires matching, always park the vehicle on a flat place.
• Arrange for necessary tools and measuring instrument (such as a TOYOTA electrical tester (SST
09082-76002-71), etc.).
Step 2 During repair
• Never use an impact wrench for removing and installing controllers and sensors.
• Do not turn the ignition key switch ON or OFF more than necessary when the sensor wiring is discon‐
nected. 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.
• When turning the solenoid (for lock cylinder) 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.
• SAS/OPS functions are suspended during matching. Do not operate the vehicle in this state.
• Do not turn the ignition key switch ON with one side (RH or LH) of a vehicle jacked up. It is very dan‐
gerous to turn the ignition key switch ON in this state as it releases the swing lock and the vehicle be‐
comes suddenly tilted.
16-640

• 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.
• When the hydraulic piping is disconnected, apply cover to the fitting and hose to prevent the dirt from
entering.
• If the oil control valve for manual lowering is loosened, tighten it to a prescribed torque.
• Tighten respective set bolts to a prescribed toque.
• Respective sensors require no adjustment during installation. Make initialization during matching.
• To disconnect a connector, do not pull it by the harness.
• When inspecting the harness, carefully operate so as not to damage connector terminals.
• The swing lock cylinder must not be disassembled. If disassembled, air enters to make it not reusable.
• Do not apply strong impacts to the frame and head guard to prevent the yaw rate sensor from being
damaged.
• 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
Step 3 Temporary measures

• If the mast should fail to lower because of some trouble, it can be lowered manually. Loosening the illus‐
trated valve on the top of the oil control valve lowers the mast. Operate the lift lever for lowering with
the manual lowering valve loosened. After the repair, tighten it appropriately.
• T = 32.0 N m [23.6 ft-lbf]
 16-641

16.2.3 SAS/OPS CONTROLLER REMOVAL AND INSTALLATION

NOTICE
Do not use an impact wrench for removing/installing the set bolts from/to the connector boot bracket and
SAS/OPS controller.

Removal Procedure
Step 1 Remove the floor mat and rear toe boad.
Step 2 Disconnect the accelerator pedal connector and wire
clamps (2 places), and remove the front toe board.
Step 3 Remove the front toe board.
Step 4 Remove the lower panel.
a 7 Step 5 Remove the instrument panel (RH).
Step 6 Remove the connector boot set plate.
Step 7 Disconnect the connector.

16

6
5

Step 8 Remove the SAS/OPS controller.

a : T = 3.3 to 7.7 N m [2.4 to 5.7 kt-lbf]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

NOTICE
• Apply locking agent (08833-76002-71) on the theaded portion of the controller set bolts and the boot set plate
set bolts tigtening them.
• Always use genuine controller set bolt. Correct tightening will fail if non-genuine bolts are used.
• When the SAS/OPS controller is replaced, perform the matching
16-642

16.2.4 YAW RATE SENSOR REMOVAL AND INSTALLATION

NOTICE
• Extremely be careful not to apply mechanical shock in order to protect the yaw rate sensor. Do not use an
impact wrench.
• Do not use the yaw rate sensor which you accidentally dropped.

Removal Procedure
Step 1 Close the LPG supply piping valve and LPG outlet
b a valve.
▪ a : LPG supply piping valve
b : LPG outlet valve

Step 2 Start the engine, and run the engine in the idling state
until it stops naturally.
Step 3 Open the LPG bracket.
3

Step 4 Open the engine hood.

Step 5 Remove the battery and battery tray.

5
 16-643

6 Step 6 Remove the relay block and injector driver set bolt to
free them. (The indector driver is for diesel engine mod-
el.)

Step 7 Remove the floor mat and rear toe board.

Step 8 Disconnect the accelerator pedal connector and the
8 wire clamps (2 places), and remove the front toe board.

16

Step 9 Drain coolant.

9

Step 10 Disconnect the piping from fuel piping assembly.

10

10
16-644

Step 11 Remove the fuel piping assembly.

11

12 Step 12 Disconnect the wiring from the slow solenoid valves.

Step 13 Disconnect the wiring from the main solenoid valves.

13

Step 14 Disconnect the wiring from the regulator ASSY.

14
 16-645

15 Step 15 Disconnect the fuel piping.

Step 16 Disconnect the hot water hose.

16
16

17 Step 17 Remove the filter and main solenoid.

18 Step 18 Remove the regulator ASSY.

16-646

Step 19 Remove the battery set plate.

19

Step 20 Disconnect the yaw rate sensor connector.

20 a

Step 21 Remove the yaw rate sensor W/ bracket.

a : T = 3.3 to 7.7N m [2.4 to 5.7ft-lbf]

Installation Procedure
The installation procedure is the reverse of the removal procedure.

NOTICE
After installing the LPG regulator, carry out gas leakage inspection.
 16-647

16.2.5 TIRE ANGLE SENSOR REMOVAL AND INSTALLATION

Removal Procedure

b
2

4
16

a : T = 0.7 to 1.3 N m [0.52 to 0.96 ft-lbf]

b : T = 10 to 16 N m [7.38 to 11.8 ft-lbf]
Step 1 Remove the sensor cover.
Step 2 Disconnect the tire angle sensor connector.
Step 3 Remove the tire angle sensor and joint.
Step 4 Remove the sensor plate.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

NOTICE
When the tire angle sensor is removed/installed or replaced, proceed with the matching procedure.

Install the tire angle sensor and joint.

Step 1 Turn the steering wheel fully clockwise and hold it
there.
16-648

Step 2 Insert the joint into the king pin groove. Apply a small
a amount of MP grease on the joint surface in contact
with the king pin and sensor plate.
▪ a : Joint,
b b : Apply MP grease

Step 3 Install the tire angle sensor by aligning it with the joint
center axis.
a ▪ a : Tire angle sensor
b : Joint

Step 4 Turn the tire angle sensor until the tire angle sensor
mounting hole is aligned with the sensor plate screw
hole. (Approx. 95°)

95°

Step 5 Fix by tightening the tapping screw after mounting hole

alignment.
 16-649

16.2.6 SWING LOCK CYLINDER REMOVAL AND INSTALLATION

Removal Procedure
Step 1 Remove the counterweight.
Step 2 Jack up the vehicle.
Step 3 Remove the swing lock cylinder lower pin.
a : T = 29.0 N m [21.4 ft-lbf]

a
3

Step 4 Disconnect the swing lock solenoid connector.

4
16

5 Step 5 Remove the swing lock cylinder upper pin.

▪ a : SST 09810-20172-71

a
16-650

Step 6 Remove the swing lock cylinder and inspect the accum-
rator.
▪ Remove the plug from the tip end of the accumla‐
tor. Use a coin or screwdriver . (After the inspec‐
tion, install the plug by pushing it with a finger.)
L
▪ Measure accumulator piston depth L.
Standard : 45 mm (1.77 in) (40°C (104°F))
Limit : 52 mm (2.05 in) (104°C (68°F))

▪ Standard cannot be judged correctly in a low tem‐

100(212)
90(194)
perature, as it fluctuates greatly by the oil tempera‐
ture inside the lock cylinder. (Refer to the graph) If
60(140) temperature is low, raise the oil temperature (ap‐
prox. 40°C (104°F): a level of human body tempera‐
30(86) ture for the cylinder body) by forward and reverse
20(68) traveling on an irregular road surface before meas‐
0(32)
uring. (Or, warm up from outside using a heater) If
-20(-4) the limit value is exceeded, replace the swing lock
52.5 50.5 45.5 40.5 35.5 32.5
(2.07) (1.99) (1.79) (1.59) (1.40) (1.28) cylinder ASSY.
51
(2.01)
▪ After inspection, push a plug in with a finger.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

NOTICE
• Apply chassis grease to the spherical portion of the upper pin and its mounting hole before installation.
• Apply thread tightener (08833-76001-71) to the threaded portions of the upper and lower pin set bolts before
tightening them.
• After installation, apply chassis grease from the grease fitting.

Step 6 Install the swing lock cylinder.

a
▪ Install with the mark (protruded portion) at the rod
end facing outward.
a : Mark

Step 5 Install the swing lock cylinder upper pin.

▪ Adjust the hole position of the swing lock cylinder
and rear axle lower pin, and install the upper pin.
 16-651

16.2.7 TILT ANGLE SENSOR REMOVAL AND INSTALLATION

Removal Procedure
Step 1 Remove the floor mat and rear toe board.
Step 2 Disconnect the accelerator panel connector and the
wire clamp (2 places), and remove the front toe board.
Step 3 Remove the front toe board.
Step 4 Remove the lower panel.
Step 5 Disconnect the tilt angle sensor link.
5

Step 6 Disconnect the connector.

Step 7 Remove the tilt angle sensor.

Installation Procedure 16
The installation procedure is the reverse of the removal procedure.

NOTICE
• Apply MP grease at the sensor and link rod end.
• When the tilt angle sensor is remove/installed or when the length of the tilt angle sensor link is adjusted or re-
placed with the re-setting procedure.
16-652

16.2.8 SPEED SENSOR REMOVAL AND INSTALLATION

Removal Procedure
Step 1 Hoist the inner mast.
3
4
Step 2 Remove the speed sensor cover.
Step 3 Disconnect the connector.
Step 4 Remove the speed sensor.

Installation Procedure
The installation procedure is the reverse of the removal procedure.

Removal and Installation

a : Wooden blocks
Support the bottom of the inner mast with wooden blocks and fix the blocks by taping onto the outer mast.
 16-653

16.2.9 LOAD SENSOR REMOVAL AND INSTALLATION

Removal Procedure
Step 1 Remove the floor mat and toe board.
Step 2 Disconnect the accelerator pedal connector and the
wire clamps (2 places).
Step 3 Remove the front toe board.
Step 4 Disconnect the connector.
Step 5 Remove the load sensor.

5 4

Installation Procedure
The installation procedure is the reverse of the removal procedure.
16
NOTICE
When the load sensor is removed/installed or replaced, proceed with the matching procedure.
16-654

16.2.10 FORK HEIGHT SWITCH REMOVAL AND INSTALLATION

Removal Procedure

b
1

a b

a : T = 16.2 to 37.8 N m [11.9 to 27.9 ft-lbf]

b : T = 7.8 to 18.2 N m [5.8 to 13.5 ft-lbf]
Step 1 Remove the connector cover.
Step 2 Disconnect the connector.
Step 3 Remove the mast lifting height switch.

Installation Procedure
The installation procedure is the reverse of the removal procedure.
 16-655

16.3 OPS FUNCTIONS

16.3.1 GENERAL
OPS system detects presence of the operator with the seat switch, and when the operator is not in the normal
operating position, it interrupts traveling power and restricts load handling operation to prevent unintentional
movements.

16.3.2 CONTROL SPECIFICATION

Step 1 Traveling OPS functions
• When the controller detects the seat switch being turned off for 2 seconds, the traveling power is inter‐
rupted by interrrupting the voltage supply to the forward and reverse drive valve in the transmission
with control of the forward interrrupt relay and the reverse interrupt relay.
• Travel OPS is released by returning the direction lever to the neutral position and turning on the seat
switch.
• On the "EZ pedal" option model [E43A], applying the parking brake mskes the direction signal neutral,
then it cancels the travel OPS.
• Moreover, it cancels the travel OPS with accelertor pedal off and press the accelrator pedal once again,
and replace the direction of the direction too.
16

NOTICE
Traveling OPS is not a brake. Engage the parking brake all the time when leaving the forklift.

Step 2 Material handling OPS system

• When the controller detects the seat switch being turned off for 2 seconds, all the load-handling opera‐
tions are restricted by valve control.
• On conventional lever models, the lock valve restricts lowering and tilt control valve and tilt backward
lock valve restricts tilting. The unload valve shuts off the hydraulic oil supply and restricts lifting and
attachment operations.
• On mini lever model [E45A], the electric proportional valves restrict the movements of lift, tilt, and at‐
tachments. At the same time, the lift lock valve and tilt control valve also restricts lowering and tilting.
• On conventional lever models, hydraulic function OPS have been released by turning the lift down lever
to the neutral position and turning on the seat switch.
• On mini lever model [E45A], the hydraulic function OPS have been released by turning all the levers to
the neutral positions and turning on the seat switch.
Step 3 OPS operation information function
• When the controller detects that the seat switch is turned off, the buzzer sound (pi-) for 1 second and the
OPS indicator shows up on the combination meter in advance of OPS activation.
• If the operator notices it and is seated again within 2 secods, the OPS will not activate. In order to inform
that the OPS is operating, the OPS indicator keeps on as long as the seat switch is being turned off.
Step 4 Return-to-neutral warning
• Traveling
16-656

• Once travel OPS is activated, the buzzer sounds continuously (pipipipi) when the seat switch is turned
on until returning the direction lever to the neutral positions. This sound informs the operator that the
vehicle is still in the travel OPS condition.
• On the "EZ pedal" option model [E43A], only releasing the accelerator pedal makes this warning cancel‐
led.
• Hydraulic function
• On conventional lever models, once hydraulic function OPS was activated, and when the seat switch is
turned on without returning the lift down lever to the neutral position, the sound (pipipipi) informs the
operator that the hydraulic function OPS is not released.
• On mini lever model [E45A], once hydraulic function OPS is activated, and when the seat switch is
turned on without returning the all the hydraulic control levers to the neutral position, the sound (pipi‐
pipi) informs the operator that the hydraulic function OPS is not released.
Step 5 Parking brake OFF warning
• The buzzer sounds when the operator leaves the seat with the parking brake released.
• The buzzer sounds when the operator turns off the key switch with the parking brake released.
• The buzzer sounds as well when operator releases the parking brake within 1 minute after turning off
the key switch.
• After the buzzer is sounding for 30 seconds for the warning, it stops sounding.