8FG D Ce048-18 - 0608 Sas-Ops

18-1
SAS/OPS
Page Page
GENERAL..............................18-2 OPS FUNCTIONS ............... 18-25 0
SAS FUNCTION ....................18-4 GENERAL ............................ 18-25 1
COMPONENTS .......................18-4 CONTROL SPECIFICATION ... 18-25
2
PRECAUTIONS FOR REPAIR 18-11 MATCHING .......................... 18-26
3
SAS/OPS CONTROLLER GENERAL ............................ 18-26
REMOVAL·INSTALLATION...18-14
BEFORE STARTING
4
YAW RATE SENSOR MATCHING ........................ 18-28 5
OPTION SET ....................... 18-32 6
TIRE ANGLE SENSOR
REMOVAL·INSTALLATION...18-16 DIAGNOSIS MEMORY........ 18-34
7
SWING LOCK CYLINDER REAR WHEEL SWING
REMOVAL·INSTALLATION...18-18 CONTROL CHECK............ 18-35 8
TILT ANGLE SENSOR PLUG-IN ANALYZER .......... 18-36 9
OPS PLUG-IN ANALYZER ..... 18-36 10
LOAD SENSOR
REMOVAL·INSTALLATION...18-21 SCREEN CONFIGURATION ... 18-36 11
SPEED SENSOR BASIC OPERATION .............. 18-37
REMOVAL·INSTALLATION...18-22 12
ANALYZER .......................... 18-41
FORK HEIGHT SWITCH 13
REMOVAL·INSTALLATION...18-23 SAS/OPS PLUG-IN
ANALYZER ........................ 18-45 14
FUNCTIONAL PARTS ............18-24
15
16
17
18
19
20
21
E
18-2
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.
Control Con
Sensor Actuator
S T K O -trol
Swing lock cylinder
(1) Fork height switch S
(Single tire only㧕
Tilt control valve
(2) Tilt angle sensor T
Lift lock valve
Knob position correcting
(3) Forward tilt switch K
valve
Output Forward interrupt relay
(4) Backward tilt switch
(toque converter vehicle only㧕
Backward interrupt relay
(5) Lower switch (toque converter vehicle only㧕
Unload valve
O Lift lock valve
(6) Load sensor Backward tilt lock valve
(Standard lever vehicle only)
(7) Fork automatic OPS lamp
leveling switch Buzzer
Input
Controller
Tilt control valve

(8) Speed sensor
S,T Error lamp
K,O Error code display
Steering wheel
(9)
angle sensor
(10) Tire angle sensor MULTI-FUNCTION display

S,T
Output (OPT)
Yaw rate sensor K,O
(11) (Bilt-in analyzer)
(Single tire only㧕
S,T
(12) Seat switch Plug-in anallyzer(SST)
K,O
Forward switch
(13) (toque converter S :Rear wheel swing control
vehicle only㧕
T :Mast tilting control
Backward switch K :Steering knob position control
(14) (toque converter
vehicle only㧕 O:OPS control
18-3
(7)
0
(1)
1
(26)
(9)(13)(14)
2
(24)(25) 3
(18)
(12) 4
(28)
5
(23)
6
7
(3)(4)(5)(6)
(16)(17)(21)(22)
8
9
(8)
10
(2)
11
(10)
(27) (19)(20) (11)
(15) 12
13
No. Name No. Name 14
(1) Fork height switch (15) Swing lock cylinder
(2) Tilt angle sensor (16) Tilt control valve
15
(3)
(4)
Forward tilt switch *1
Backward tilt switch *1
(17)
(18)
Lift lock valve
Knob position correction valve
16
(5)
(6)
Lower lift switch *1
Load sensor
(19)
(20)
Forward interrupt relay
Reverse interrupt relay
17
(7) Fork automatic leveling switch (21) Unload valve 18
(8) Speed sensor (22) Backward tilt lock valve
(9) Steering wheel angle sensor (23) Buzzer 19
(10) Tire angle sensor (24) OPS lamp
(11) Yaw rate sensor (25) Error lamp, Error code display 20
(12) Seat switch (26) Multi-function display
(13) Forward switch (27) Plug-in analyzer 21
(14) Reverse switch (28) SAS/OPS controller
*1 For the mini lever/joystick vehicles, (3) (4) and (5) switches are the lever angle sensors.
E
18-4
SAS FUNCTION
COMPONENTS
Controller
1910
Yaw Rate Sensor
5803
18-5
Tire Angle Sensor
4301
Tire angle sensor

0
1
2
3
4
5
6
7
8
9
10
Swing Lock Cylinder
11
4301
12
13
Swing lock cylinder
14
15
16
17
18
19
20
21
E
18-6
Steering Knob Position Correcting Valve
4503
Steering knob position

correcting valve
Fork Height Switch (V Mast) (1·K2·K3·2·3 ton series)
5803
18-7
Fork Height Switch (V Mast) (J3.5 ton series)
5803
Fork Height Switch (FV Mast)
5803
18-8
Fork Height Switch (FSV Mast) (1·K2·K3·2·3 ton series)
5803
Fork Height Switch (FSV Mast) (J3.5 ton series)
5803
18-9
Tilt Angle Sensor
5803
Load Sensor
5803
18-10
Speed Sensor
5803
18-11
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, 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) 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
18-12
3. Temporary measures
If the mast should fail to lower because of some trouble, it can
be lowered manually.
Loosening the illustrated 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 (326 kgf·cm) [23.6 ft·lbf]
18-13
4. Precautions for vehicle modification

H (fork height): mm (in)
No. Content of modification Condition Content of work

Change the controller. (for vehicle without swing
1 Single tire → Double tire — control)
Remove the lock cylinder.
Change the controller. (for vehicle with swing control)
2 Double tire → Single tire — Change the rear axle beem.
Install the lock cylinder.
3 Installation/Removal of attachment — Install or remove attachments.
When temporarily replace/use SAS/OPS
controllers between different vehicles
4 (However, this should be done only — Perform SET-5 of the matching
between the ones with the identical part
number.)
Note:
• Proceed with the alignment (matching) procedure after the above-mentioned modification.
(See page 18-26.)
• When placing a supply order for a mast ASSY, place order for sensors (for lifting height switch, mast
harness and other SAS related parts) simultaneously if such parts are required.
18-14
SAS/OPS CONTROLLER REMOVAL·INSTALLATION

Note:
Do not use an impact wrench for removing/installing the set bolts from/to the connector boot bracket and
SAS/OPS controller.
T = N·m (kgf·cm) [ft·lbf]
T = 5.5 (56.1) [4.1]
4
7
Removal Procedure
1 Remove the lower panel.
2 Remove the toe board.
3 Remove the shift lever box upper cover and lower cover. (M/T vehicle)
4 Disconnect the tilt lever rod.
5 Remove the connector boot bracket.
6 Disconnect the connector.
7 Remove the SAS/OPS controller.
Installation Procedure
The installation procedure is the reverse of the removal procedure.
Note:
When the SAS/OPS controller is replaced, perform the matching (See page 18-26).
18-15
YAW RATE SENSOR REMOVAL·INSTALLATION

Note:
• 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.
5
T = 5.5 (56.1) [4.1]
Removal Procedure
1 Remove the battery.
2 Remove the relay block from the battery set plate.
3 Remove the battery set plate.
4 Disconnect the yaw rate sensor connector.
5 Remove the yaw rate sensor W/ bracket.
18-16
TIRE ANGLE SENSOR REMOVAL·INSTALLATION

1
3
4
T = 10 ~ 16 (100 ~ 160) [7.2 ~ 12]
Removal Procedure
1 Remove the harness protector.
2 Remove the sensor cover.
3 Disconnect the tire angle sensor connector.
4 Remove the tire angle sensor and joint. [Point 1]
5 Remove the sensor plate.
The installation procedure is the reverse of the removal porcedure.
Note:
When the tire angle sensor is removed/installed or replaced, proceed with the matching procedure.
Joint Point Operations

[Point 1]
Installation:
Apply grease
1. Turn the steering wheel fully clockwise and hold it there.
2. Insert the joint into the kingpin groove. Apply a small amount of
MP grease on the joint surface in contact with the king pin and
sensor plate.
18-17
Tire angle 3. Install the tire angle sensor by aligning it with the joint center
sensor axis.
Joint
4. Turn the tire angle sensor until the tire angle sensor mounting
hole is aligned with the sensor plate screw hole.
(Approx. 180°)
5. Fix by tightening the tapping screw after mounting hole

alignment.
18-18
SWING LOCK CYLINDER REMOVAL·INSTALLATION

5
4 6
T = 29.0 (296) [21.4]
T = 29.0
(296) [21.4]
Removal Procedure
1 This is not applicable to 1-ton series vehicles.
Remove the radiator.
2 Jack up the vehicle.
3 Remove the lower pin and swing lock cylinder.
4 Disconnect the swing lock solenoid connector.
5 Remove the upper pin and swing lock cylinder. [Point 1]
6 Remove the swing lock cylinder. [Point 2]
Note:
• Apply chassis grease to the spherical portion of the upper pin and its mounting hole before installation.
• Apply thread tightener (08833-76001-71 (08833-00070)) to the threaded portions of the upper and lower
pin set bolts before tightening them.
• After installation, apply chassis grease from the grease fitting.
18-19
SST
Point Operations
[Point 1]
Removal:
SST 09810-20172-71
[Point 2]
Inspection:
Measure accumulator piston depth L.
1. Remove the plug, with a coin (or a screw driver) from the
center at the end of the accumulator.
2. Using a caliper, measure depth L of the accumulator piston.

Standard
46 mm (1.81 in) (20°C (68°F)),
42 mm (1.65 in) (40°C (104°F))
L Limit
52 mm (2.05 in) (20°C (68°F)),
48 mm (1.89 in) (40°C (104°F))
Temperature °C (°F) Standard cannot be judged correctly in a low temperature, as it

60
fluctuates greatly by the oil temperature inside the lock
(140) cylinder. (Refer to the graph)
40
(104)
If temperature is low, raise the oil temperature (approx. 40°C
(104°F): a level of human body temperature for the cylinder body)
20
(68) by forward and reverse traveling on an irregular road surface
0 before measuring. (Or, warm up from outside using a heater)
(32)
If the limit value is exceeded, replace the swing lock cylinder
-20
(4)
52 50 48 46 44 42 40 38
ASSY.
(2.05) (1.97) (1.89) (1.81) (1.73) (1.65) (1.57) (1.50)
3. After inspection, push a plug in with a finger.
L dimension mm (in)
Installation:
Install with the mark (protruded portion) at the rod end facing
outward.
18-20
TILT ANGLE SENSOR REMOVAL·INSTALLATION

3 4
T = 17.0
(173)
[12.5]
T = 17.0
(173)
[12.5] 5
Removal Procedure
3 Disconnect the tilt angle sensor link rod.
5 Remove the tilt angle sensor W/ bracket.
6 Remove the tilt angle sensor.
7 Remove the link shaft and link lever.
Note:
• Apply MP grease on the spherical portion of the link arm, inside the oil seal and inside the bushing, and
then install.
• Apply thread tightener (08833-76001-71 (08833-00070)) to the threaded portion of the tilt angle sensor
installation screws and the link lever installation nuts, and tighten them.
• Perform matching if the tilt angle sensor is removed or installed, or the tilt angle sensor link is replaced.
(Refer to page 18-26)
18-21
LOAD SENSOR REMOVAL·INSTALLATION

T = 22.0 ~ 26.0
(224 ~ 265)
[16.2 ~ 19.2]
Removal Procedure
4 Remove the load sensor.
Note:
When the load sensor is removed/installed or replaced, proceed with the matching procedure.
(See page 18-26.)
18-22
SPEED SENSOR REMOVAL·INSTALLATION

T = 3.0 ~ 7.0
1
(31 ~ 71)
[2.2 ~ 5.2] 3
Removal Procedure
1 Remove the speed sensor cover.
3 Remove the speed sensor.
18-23
FORK HEIGHT SWITCH REMOVAL·INSTALLATION

V mast
1·K2·K3·2·3 ton
T = 15 ~ 25 (153.0 ~ 254.9) [11.1 ~ 18.4]
2 J3.5 ton
T = 27 (275.3) [19.9]
1
(J3.5 Vehicle only)
T = 13
(132.6)
[9.6]
FV·FSV mast
T = 13 (132.6) [9.6]
T = 27 (275.3) [19.9]
Removal Procedure
1 Remove the lower cover.
3 Remove the fork height switch.
18-24
FUNCTIONAL PARTS
Note:
• Refer to section 9 (STEERING) for the steering angle sensor. Refer to section 16 (OIL CONTROL VALVE)
for the solenoids installed at the oil control valve and the tilt lever knob switch.
• Refer to section 20 (TROUBLESHOOTING) for inspection of functional components.
18-25
OPS FUNCTIONS
GENERAL
OPS system detects the operator with the seat switch, and if the operator is not in the proper driving position, it cuts
off the driving force while limiting the material handling operation.
However, M/T vehicles do not have traveling OPS functions.
CONTROL SPECIFICATION
1. Traveling OPS functions (T/C vehicle only)
If the controller detects that the seat switch is OFF for 2 seconds, it will cut off the driving force by interrupting the
voltage supply line to the forward/reverse drive valve of the torque converter through the control of forward
traveling and reverse traveling interruption relays.
While the seat switch is ON, traveling OPS state is cancelled by shifting the forward-reverse travel lever back to
neutral.
2. Material handling OPS system
(1) STD lever vehicle
If the controller detects that the seat switch is OFF for 2 seconds, it will stop the operations of lift lowering
and forward/backward tilting by controlling the lift lock valve, tilt control valve and backward tilt lock valve.
For lifting and attachment, the material handling operation will be stopped by cutting off the hydraulic oil
supply through the control of the unload valve.
In addition, the material handling OPS state is cancelled in the following conditions according to material
handling operations.
(a) Lowering: when the seat switch is ON, and the lift lever is set to the condition other than lowering.
(b) Other than lowering: when the seat switch is ON for more than 1 second.
If you operate the attachment lever while OPS is operated, it may move by the attachment's own weight, or
by the back pressure of the unload valve.
(2) Mini lever/joystick vehicle (OPT)
If the controller detects that the seat switch is OFF for more than 2 seconds, lifting, tilting and attachment
operations will be stopped by controlling the solenoid valves.
Material handling OPS state is cancelled when the seat switch is ON, and all the levers are shifted back to
neutral.
3. OPS operation notification functions
If the controller detects that the seat switch is OFF, the buzzer will sound for approx. 1 second and the OPS light
will turn on to notify the operator that OPS is going to be activated. In addition, the OPS light stays on while the
seat switch is OFF to notify that it is in the OPS state.
4. Return-to-neutral warning
After the traveling OPS is activated, if the seat switch turns ON without shifting the forward-reverse travel lever
back to neutral, the buzzer will sound (repeated beeps) to notify the operator that traveling OPS is not cancelled.
(1) STD lever vehicle
After material handling OPS is activated, if the seat switch turns ON while leaving the lift lever at the
lowering operation, buzzer will sound (repeated beeps) to notify the operator that the lowering operation
stop is not cancelled.
(2) Mini lever/joystick vehicle (OPT)
After material handling OPS is activated, if the seat switch turns ON without shifting all the material handling
levers to neutral, buzzer sounds (repeated beeps) to notify the operator that the material handling OPS is
not cancelled.
18-26
MATCHING
GENERAL
• For the tilt angle, load and tire angle sensors among sensors used for SAS functions, the signal voltage values
under the mast vertical, no load, tire straight and rear axle beam horizontal conditions are stored in the
controller for control based on these values. When servicing these sensors or replacing related parts, matching
(updating the sensor signal voltage under the standard vehicle condition) is necessary. In addition, matching is
required for the tilt angle sensor if the vehicle posture changes considerably, and for the material handling
sensor, when the loading in no-load state changes as a result of adding/removing the attachment, replacing the
mast, change in the fork length or removing/installing the fork.
There are two methods of matching: using the hour meter and tilt knob switch; and using the plug-in analyzer
(SST part number 09240-26600-71) (refer to 20-58).
• Each lever angle sensor for mini lever or joystick function is controlled based on the signal voltage value stored
in the controller with each lever neutral at the time of shipment. When servicing these sensors or replacing
related parts, matching (updating the sensor signal voltage under the standard vehicle condition) is necessary.
• Live load gauge stores mast specification information and signal voltage values of the load sensor during no-
load to the multi-function display, and indicates based on these information. When servicing the mast or load
sensor or replacing related parts, matching (updating the sensor signal voltage with the mast specification
information or under the standard vehicle condition) is necessary.
Matching Items and Prerequisite for Implementation

1. SAS
Prerequisite for
No. Indication Description
implementation
Tilt angle sensor output with fork in the horizontal position is stored in
1 TILTL *1,*2,*3,*6,*7,*8
the controller.
Tilt angle sensor output with the forward tilt control the mast vertical
2 TILTF LOAD standard condition, and the load sensor output in the no-load *1,*2,*3,*4,*6,*7,*8
condition are stored in the controller.
Tire angle sensor output in the condition of the vehicle traveling
3 TIRE *1,*5
straight ahead is stored in the controller.
4 SWING — —
2. MINI LEVER (OPT: mini lever or joystick vehicle only)

Prerequisite for
implementation
Lift lever angle sensor output with the lift lever in the neutral position
6 LEVER1 *1,*9
is stored in the controller.
Tilt lever angle sensor output with the tilt lever in the neutral position
7 LEVER2 *1,*10
is stored in the controller.
Attachment (1) lever angle sensor output with the attachment (1)
8 LEVER3 *1,*11
lever in the neutral position is stored in the controller.
Attachment (2) lever angle sensor output with the attachment (2)
9 LEVER4 *1,*12
lever in the neutral position is stored in the controller.
18-27
3. LOAD METER (OPT: vehicle with multi-function display DX model only)

Prerequisite for
implementation
Number of the mast lift cylinders is stored.
10 LIFT CYL. NUMBERS *7,*13
(Total number including front and rear)
11 LIFT CYL. BORE Bore of the lift cylinder is stored. *7,*13
12 LOADMETER 0 SET 0 point of the load gauge is stored. *4,*6,*7,*13
When you want to
13 COMPENSATION Accuracy of the load meter is adjusted.
adjust the accuracy
Prerequisite for implementation

*1 When replacing the SAS/OPS controller
*2 When removing/installing or replacing the tilt angle sensor
*3 When changing the tilt angle sensor rod length or replacing the rod
*4 When removing/installing or replacing the load sensor
*5 When removing/installing or replacing the tire angle sensor/sensor cover
*6 When removing/installing or changing the attachment and fork
*7 When replacing the mast
*8 When replacing the tilt cylinder
*9 When replacing the lift lever angle sensor
*10 When replacing the tilt lever angle sensor
*11 When replacing the attachment (1) lever angle sensor
*12 When replacing the attachment (2) lever angle sensor
*13 When replacing the multi-function display
18-28
BEFORE STARTING MATCHING

Set the vehicle to "Standard vehicle condition" before starting matching.
"Standard vehicle condition" means that the vehicle satisfies the conditions described below.
Standard Vehicle Condition

Note:
• Items 1 ~ 4 below show the standard vehicle condition for
SAS matching.
• Before carrying out matching for mini lever/joystick
vehicles, move the armrest to the driving position and
check the neutral state of the levers.
1. Tire pressure check
Adjust the tire pressure to the specified level. Matching will be
Level surface inaccurate if the pressure is low, or if there are air pressure
fluctuations between front and rear as well as left and right.
V mast FV·FSV mast 2. Surface levelness check

If matching is conducted on an inclined or rough floor surface,
errors in standard vehicle condition will occur, so perform
matching on a flat, level surface (inclination: within 0.5°).
3. No-load vertical condition check
Store the output voltage of the load sensor in no-load state in
the controller. At this time, the following conditions must be
satisfied:
500 mm 100 mm (1) For the V mast, set the lifting height to about 500 mm
(19.7 in) (3.93 in) (19.7 in) and use a goniometer to check that the mast is
vertical.
(2) For the FV/FSV mast, set the rear cylinder rod projection
to about 100 mm (3.93 in) and use a goniometer to check
that the mast is vertical.
(3) Set the mast in the vertical position from the backward
tilted position by operating the tilt lever in the forward
tilting direction.
4. Tire straight traveling position check

Store the tire angle sensor output voltage in the controller in
the condition of the vehicle traveling straight ahead.
50 mm Condition of the vehicle traveling straight ahead means that
(2.0 in) the deviance to left or right is within 50 mm (2.0 in) when the
50 mm vehicle travels for 5 meters (16 ft) with the steering being fixed.
(2.0 in)
5. Loadmeter 0 set (0 set of the load gauge) check
For all the V/FV/FSV mast, the mast is to be vertical and the
5 m (16 ft) fork height is to be 500 mm (19.7 in).
18-29
Matching connector Matching Procedure

When there is a matching connector (STD lever vehicle)
Note:
Turning the ignition key switch ON (or starting the engine)
after disconnecting the matching connector causes an error
(error code 41-1) to be displayed and stored in the SAS/OPS
controller, for which care must be taken.
1. Turn the ignition key switch ON (or start the engine).
2. Disconnect the matching connector.
The hour meter indicates "PASS_", the wrench lamp turns on,
and then password display is indicated.
Tilt knob switch 3. While shifting the tilt lever to backward tilt for more than 5
seconds, returning the lever and tilt knob switch after pressing
the switch for more than 2 seconds will indicate "1-dIAG" on
the hour meter.
Menu No. Menu description
1-dIAG Diagnosis memory menu
2-OPT Option set menu
3-SET Matching menu
4-SAS Rear wheel swing control check menu
18-30
Tilt knob switch 4. Operate the tilt lever to indicate "3-SET" and press the tilt knob
switch to display "SET1-". Set number display changes as
indicated in the table below each time the tilt knob switch is
pressed for less than 2 seconds.
Set No. Description of matching
SET1 Fork stop position with automatic leveling
Forward tilting limit position and
SET2
no-load standard load
SET3 Tires in straight traveling position
SET4*1 —
SET5*2,*3 Deleting engine and display ECU information
*1: Indication may be made but actually it is not used.

*2: Indicates only when CAN communication abnormalities (AD-1
or AD-7) occur.
*3: Perform SET5 when temporarily replacing SAS/OPS controller
between the different vehicles.
Note:
When switching the matching menu, do not press the tilt knob
switch for more than 2 seconds. Pressing the switch for more
than 2 seconds will carry out the displayed matching.
O display
5. Operate the tilt lever to indicate "3-SET" and press the tilt knob
switch for more than 2 seconds to carry out matching.
O indication: Matching is completed. (Wrench lamp starts to
blink)
H indication: Check for the sensor abnormality,
disconnection of the harness and the short-
H display circuit since the signal voltage value is outside
the matching rang. (Refer to the troubleshooting
section.)
Note:
• For re-matching, repeat step 5.
• To make a separate matching, repeat steps 4 to 5.
6. Connect the matching connector and turn the ignition key
switch OFF.
18-31
When There is No Matching Connector

(Mini Lever/Joystick Vehicle)
Note:
• Even when there is no matching connector, engine and
display ECU information can be deleted.
• Refer to the multi-function display for SAS matching.
(Section 20)
1. Turn the ignition key switch ON (engine stop).
2. Display the mask menu on the multi-function display or multi-
function display DX. (refer to page 20-14)
3. Keep pressing the fork automatic leveling switch for more than
Fork automatic leveling switch
2 seconds to display the matching menu.
Note:
• Only SET5 when there is a matching connector, will be
indicated.
• Indicated only when CAN communication abnormalities
(AD-1 or AD-7) occur.
4. Keep pressing the fork automatic leveling switch for more than
2 seconds to delete the information.
0 indication: deleting the information is completed. (Wrench
O indication (Deleting information) light will be flashing)
5. Turn the ignition key switch OFF.
18-32
OPTION SET
The option set function is to invalidate the mast forward tilting angle control. There are two methods to do this; one is
to use the hour meter and tilt knob switch and the other method is to use the plug-in analyzer (SST). (See section
20.)
Caution:
When the option set is changed, perform maintenance of the caution label of “CAUTION FOR OPERATION.”
Matching connector Option Set Procedure

Note:
3. While shifting the tilt lever to backward tilt for more than 5
the hour meter.
4. Operate the tilt lever to indicate "2-OPT" and press the tilt knob
switch to display "1-dIAG".
5. The displayed set number changes each time the knob switch
is pressed for less than 2 seconds.
Option No. Control name
OPT1 Mast forward tilt angle control
OPT2* —
OPT3 (Unused: always n)
*: Displayed but not in use.

6. Keep the knob switch pressed until the wrench lamp starts
blinking (for 2 seconds or over) to change y to n, and n to y.
y: Control valid
n: Control invalid
switch OFF.
18-33
8. Perform the maintenance of the caution label.

Material handling swing lock control If the control is invalidated:
Remove the pertinent validation indication to replace with
invalid indication.
If the control is validated:
Replace the caution label to indicate valid control.
Mast forward tilt angle control
Note:
When mast front tilt angle control is invalidated, and T-OFF
When mast forward tilt angle control display will be indicated for 10 seconds when the ignition key
is invalidated:
switch is turned ON.
18-34
DIAGNOSIS MEMORY
There are two methods of diagnosis memory for STD lever vehicles: using the hour meter and tilt lever; and using the
plug-in analyzer (SST) (refer to page 20-22).
Refer to troubleshooting (refer to section 21) for the diagnosis code list.
Matching connector Diagnosis Memory Procedure

Note:
the hour meter.
4. As you press the tilt knob switch for less than 2 seconds, the
diagnosis No. and the error code will be indicated, and each
error code and the time when it occurred will be indicated
alternately every 2 seconds.
Note:
• The maximum number of error codes that can be stored is
10, and as the diagnosis number gets smaller, the error
will be newer.
• The error detected when turning the ignition key switch
ON may be stored with the memory time as 0.0.
switch OFF.
18-35
REAR WHEEL SWING CONTROL CHECK

There are two methods of the rear wheel swing control check: using the hour meter and the tilt lever; and using the
plug-in analyzer (SST) (refer to page 20-32).
Matching connector Rear Wheel Swing Control Check Procedure

Note:
the hour meter.
4. Operate the tilt lever until "4-SAS" is indicated.
5. When you press the tilt knob switch, two segments rotate, and
indication that the rear wheel swing lock control is being
checked is displayed. (Wrench lamp is ON)
6. Check the rear wheel swing lock control by driving the vehicle.
While the rear wheel swing lock control is operated (during
locking), the wrench lamp turns on.
switch OFF.
18-36
PLUG-IN ANALYZER
OPS PLUG-IN ANALYZER
For the maintenance and service of OPS functions, a separate type plug-in analyzer is introduced as an SST
(Special Tool for Service).
The plug-in analyzer is designed to read the operating state of sensors and actuators used for the OPS functions and
the error information detected by the controller. It serves to check on the operating state of OPS functions and
shortens the repair time for a problem. Moreover, it is equipped with a save function to file data displayed on the
screen in the SST.
SST 09240-23323-71
Menu name Content of function Reference page

with the OPS controller on
DIAG MEMORY Indication of ten error codes and sub-codes in past. 18-41
Communication function
the vehicle side
Monitoring input voltage value from the sensors and the output
IN/OUT MONITOR 18-42
signal, etc. to the solenoid, etc.
OPS
ACTIVE TEST Forced operation of solenoids and warning lamps. 18-43
CONTROLLER DATA Indication of OPS controller abbreviation number and version 18-44
SCREEN CONFIGURATION
MAIN MENU
1.SAS NO USED
2.OPS ANALYZER MENU

1.DIAG‫ޓ‬MEMORY DAIG MEMORY(1/1)
2.IN/OUT MONITOR IN/OUT MONITOR(1/3)
IN/OUT MONITOR(2/3)
IN/OUT MONITOR(3/3)
3.ACTIVE TEST ACTIVE TEST(1/1)
4.CONTROLLER DATE CONTOLLER DATE(1/1)
7.END
7.TESTER SET TESTER SET MENU

1.CONTRAST SET CONTRAST SET
2.LANGUAGE SET LANGUAGE SET
3.FILE INITIALIZER FILE INITIALIZE
7.END
18-37
BASIC OPERATION
Name of sections and the switch functions
Position of
Name of section Mark Function Switch
indication
Main unit • Moves the cursor to the above item.

• Moves to the preceding page.
Selector
A • Moves the cursor to right or left. switch c
<Blank> <No function>

Connector
• Selects the item below.
Switch • Moves to the following page.
Screen title A Selector
B
switch d
<Blank> <No function>
• Determines an item for selection.

Menu
C
switch e
B C Switch mark indicator
<Blank> • Moves to MENU screen.
Caution on using:
• Operate the switch with finger tip.
• Do not apply strong impact from dropping or collision.
• Do not leave it under the direct rays of the sun for long time.
Connection and Operation of SST

2. Open the diagnosis connector cover of the vehicle and
properly connect the connector on the SST side.
SST 09240-23323-71
Note:
Since the connector has no locking device, securely connect
Diagnosis it to prevent contact defect upon closing the engine hood with
connector the connector in connected state.
3. Turn the ignition key switch ON or start the engine.

4. Display of the initialization screen
After about 15 seconds of display, "LANGUAGE SET" or
"MAIN MENU" screen appears. The screen may be changed
during this period by pressing the menu switch e.
18-38
5. "LANGUAGE SET" screen

Since this screen appears only when the language is
undefined, determine a language to use for display.
(1) Select a display language by pressing selector switch c
or d.
• Japanese
• English
(2) Press MENU switch e to determine the language setting.
Note:
Once the display language is defined, "LANGUAGE SET"
screen will not be displayed from the next time onward. To
change the language, go to "TESTER SET".
6. "MAIN MENU" screen

(1) Select the menu using selector switch c and d and
determine by pressing MENU switch e.
• SAS: Not used.
• OPS: Moves to OPS ANALYZER MENU screen.
• TESTER SET: Moves to "TESTER SET" screen.
18-39
7. "TESTER SET" screen

(1) Select the menu using selector switch c and d and
determine by pressing MENU switch e.
(a) CONTRAST SET: Moves to "CONSTAST SET"
screen to adjust the contrast. (Refer to step 8)
(b) LANGUAGE SET: Moves to "LANGUAGE SET"
screen to select the language. (Refer to step 9)
(c) FILE INITIALIZE: Moves to "FILE INITIALIZE"
screen to initialize data in the main unit. (This is not
used for OPS)
(d) END: Returns to MAIN MENU screen.
8. "CONTRAST SET" screen

(1) Select a contrast level using selector switch c and d
Contrast level: 1 (Light) to 8 (Dark)
(2) Press MENU switch e to store the contrast level and
return to "TESTER SET" screen.
18-40
9. "LANGUAGE SET" screen

(1) Select the language using selector switch c or d.
(a) Japanese
(b) English
(2) Press MENU switch e to determine the language and
display SAVING → COMPLETE in the message column.
(3) Select "ENG" using selector switch c or d and press
MENU switch e to return to "TESTER SET" screen.
10. "FILE INITIALIZE" screen
This is not used for OPS.
Removal of SST
1. Check that the screen title is for one of the MENU screens.
3. Disconnect the connector.
Note:
To disconnect, hold the body of the connector.
4. Close the diagnosis connector cover.
18-41
ANALYZER
ANALYZER MENU Display contents and function Page
1. DIAG MEMORY Indication of error codes for 10 most recent errors 18-41
2. IN/OUT MONITOR Indication of operating conditions of vehicle electrical system 18-42
3. ACTIVE TEST Forced operation signal output to the selected item 18-43
4. CONTROLLER DATA Indication of the OPS controller abbreviation number and version 18-44
Operation Procedure
1. Select and enter "2OPS" on the main menu screen to display
the OPS ANALYZER MENU screen.
2. "ANALYZER MENU" screen

(1) Move the cursor to the desired menu by operating
selector switch c or d, and enter by operating MENU
switch e.
(2) Select and enter "END" to return to the "MAIN MENU"
screen.
"1 DIAG MEMORY"

This screen displays ten error codes from the most recent one.
[Explanation on display contents]
(1) Order of error occurrence
(2) Error codes
[Clear memory]
Press selector switch c continuously for 2 seconds.
(1) (2)
[End]
Press MENU switch e to return to the "ANALYZER MENU" screen.
Note:
• Only "-" appears at the end of the item involving no error
occurrence.
• If reception has not been completed, only the number
appears without "-" indication.
18-42
"2 IN/OUT MONITOR" (Excluding the mini-lever

vehicle)
(1)
(2) (1) SEAT: Seat switch input signal
(3) (2) DIR: Direction switch input signal (T/C vehicle only)
FWD: Forward direction switch input signal
(4) REV: Reverse direction switch input signal
(3) RLY: Output signal from the forward/reverse travel

interruption relay and backward tilt lock solenoid
FWD: Output signal to the forward/reverse travel
(1) interruption relay (T/C vehicle only)
(5) REV: Output signal to the backward tilt lock
(6)
(7)
solenoid
(8)
(4) VOLTAGE: OPS controller power supply voltage
(4)
(5) LIFT LOWER: Lift lowering switch input signal
(6) UNLOAD SOL: Output signal to the unload solenoid
(7) LWR SOL: Output signal to the lowering lock solenoid
(8) TILS SOL: Output signal to the tilt solenoid

(9) TILT: Tilt lever switch input signal
FWD: Forward tilt switch input signal
(1)
(9)
BWD: Backward tilt switch input signal
CONT: No used
(8) (10) LSOPT: Backup.
(10)
(4) [End]
Press MENU switch e to return to the "ANALYZER MENU" screen.
18-43
"3 ACTIVE TEST" (Excluding the mini-lever vehicle)

Note:
ON indication on the screen shows the controller output state.
(1)
(2) The operation, therefore, should be checked visually, by
(3) operating sound, etc.
(4)
(5) 1. Select the item by selector switch d, and set OFF/ON by
(6) selector switch c.
(7)
(1) RLY FWD*
Set to ON for forced output of forward/reverse travel
interruption relay activation signal. (Forward/reverse
travel disabled state)
(2) RLY REV
Set to ON for forced output of backward tilt lock solenoid
activation signal. (Backward tilt disabled state)
(3) UNLOAD SOL
Set to ON for forced output of unload solenoid activating
signal. (Material handling disabled state)
(4) LWR SOL
Set to ON for forced output of lowering lock solenoid
activating signal. (Lowering enabled state)
(5) TILT SOL
Set to ON for forced output of tilt solenoid activating
signal. (Forward tilting enabled state with backward tilting
speed restriction)
(6) LAMP
Set to ON for forced output of OPS lamp lighting signal.
(OPS lamp lighting state)
(7) BUZZER
Set to ON for forced output of OPS buzzer sounding
signal. (Continuous OPS buzzer sounding)
* The drive power interrupting function is not provided on the
manual transmission vehicle.
2. After resetting all items to OFF, press MENU switch e to return
to the "ANALYZER MENU" screen.
18-44
M/T "4 CONTROLLER DATA"

The OPS controller abbreviation No. and version No. can be
displayed on this screen.
(1) DATA
Controller abbreviation No.
(2) VER
Version No.
T/C [End]
Press MENU switch e to return to the "ANALYZER MENU"
screen.
18-45
SAS/OPS PLUG-IN ANALYZER

SST 09240-26600-71 For the maintenance and servicing of SAS/OPS controller, a
separate-placement type plug-in analyzer is added as SST
(servicing special tool).
The plug-in analyzer can read the operation states of the sensors
and actuators used for each controller, and error information
detected by the controllers, which is useful in checking the
operation state of each function and in saving repair time when a
defect occurs.
Mask Function List

Application
Function Description When replacing
Others
board
Displays the vehicle's electrical system
Upon vehicle
Analyzer operating status and reads the error —
abnormality
information detected by controllers.
Makes fine adjustment of traveling and c Requests from
Tuning
material handling functions. *2 users
Sets each vehicle option and other c
Specification setting —
specifications. *1 *2
Option Setting
Each control function c
Enables or disables each control function —
enable/disable *2
Updates voltage values of sensor signals c
Matching —
under the standard vehicle condition. *2
Engine idle adjustment c Requests from
Adjusts engine idle speed.
(4Y-E engine vehicle only) *2 users
Adjusts the contrast of the plug-in analyzer
Contrast — —
display screen.
*1: This matches the controller and screen control according to the installed options and control functions equipped
on the vehicle; note that this function does not enable or disable the option or control function itself.
*2: SAS/OPS controller board
Note:
Refer to the multi-function display (Section 20) for the functions of the plug-in analyzer.

8FG D Ce048-18 - 0608 Sas-Ops

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18-1

Tilt control valve

(10) Tire angle sensor MULTI-FUNCTION display

Yaw Rate Sensor

Tire Angle Sensor

Tire angle sensor

Steering Knob Position Correcting Valve

Steering knob position

Fork Height Switch (V Mast) (1·K2·K3·2·3 ton series)

Fork Height Switch (V Mast) (J3.5 ton series)

Fork Height Switch (FV Mast)

Fork Height Switch (FSV Mast) (1·K2·K3·2·3 ton series)

Fork Height Switch (FSV Mast) (J3.5 ton series)

Tilt Angle Sensor

PRECAUTIONS FOR REPAIR

1. Preparation for repair

4. Precautions for vehicle modification

No. Content of modification Condition Content of work

SAS/OPS CONTROLLER REMOVAL·INSTALLATION

T = 5.5 (56.1) [4.1]

YAW RATE SENSOR REMOVAL·INSTALLATION

TIRE ANGLE SENSOR REMOVAL·INSTALLATION

T = 10 ~ 16 (100 ~ 160) [7.2 ~ 12]

Joint Point Operations

5. Fix by tightening the tapping screw after mounting hole

SWING LOCK CYLINDER REMOVAL·INSTALLATION

T = 29.0 (296) [21.4]

2. Using a caliper, measure depth L of the accumulator piston.

Temperature °C (°F) Standard cannot be judged correctly in a low temperature, as it

TILT ANGLE SENSOR REMOVAL·INSTALLATION

LOAD SENSOR REMOVAL·INSTALLATION

SPEED SENSOR REMOVAL·INSTALLATION

FORK HEIGHT SWITCH REMOVAL·INSTALLATION

Matching Items and Prerequisite for Implementation

2. MINI LEVER (OPT: mini lever or joystick vehicle only)

3. LOAD METER (OPT: vehicle with multi-function display DX model only)

Prerequisite for implementation

BEFORE STARTING MATCHING

Standard Vehicle Condition

V mast FV·FSV mast 2. Surface levelness check

4. Tire straight traveling position check

Matching connector Matching Procedure

*1: Indication may be made but actually it is not used.

When There is No Matching Connector

Matching connector Option Set Procedure

*: Displayed but not in use.

8. Perform the maintenance of the caution label.

Mast forward tilt angle control

Matching connector Diagnosis Memory Procedure

REAR WHEEL SWING CONTROL CHECK

Matching connector Rear Wheel Swing Control Check Procedure

Menu name Content of function Reference page

the vehicle side

ACTIVE TEST Forced operation of solenoids and warning lamps. 18-43

2.OPS ANALYZER MENU

7.TESTER SET TESTER SET MENU

Main unit • Moves the cursor to the above item.

<Blank> <No function>

• Determines an item for selection.

Connection and Operation of SST

3. Turn the ignition key switch ON or start the engine.

5. "LANGUAGE SET" screen

6. "MAIN MENU" screen