Toyota integrates Tier IV power in 8,000–17,000-lb. lift truck series

Toyota Material Handling, U.S.A., Inc. begins production this month on the 8-Series large capacity lift truck line equipped with new Toyota-designed and built four-cylinder, high-performance engines. Manufactured at the Toyota Industrial Equipment Mfg. plant in Columbus, Ind., the series features 8,000- to 17,500-lb. pneumatic models with power options including the new 1KD diesel engine.

“Forklift users in virtually any work environment can now experience the next generation of powerful ‘workhorses’ fueled by the industry’s cutting-edge engine technology,” says Toyota Material Handling President Jeff Rufener. “We designed 8-Series models to benefit our customers by delivering significant fuel savings without the sacrifice of performance.”

Improving reliability and maximizing uptime were key targets, he adds. The redesigned chassis features fully stamped steel plate side panel construction and a significant reduction over prior models’ cosmetic sheet metal and plastic. Critical controllers and relays are protected in a sealed box and new water-resistant connectors help guard against damage when working in adverse weather conditions or corrosive applications.

Rear combination lights are mounted high on the trucks’ overhead guard for improved protection; long-life LED combination lights are available for added reliability. In addition, an improved cooling system featuring a 55 percent larger radiator than earlier models’ and an external hydraulic cooler provide extra capacity to handle working in high temperature environments. A standard protection system automatically reduces the engine’s output if the coolant temperature rises to potentially damaging levels.

Toyota Material Handling officials cite operator comfort as a top priority in their new large capacity lift truck line. Ergonomic improvements have been made to the floor space, entry step, a curvilinear overhead guard post shape and a smaller diameter steering wheel. Features like the new 12-in. long dual operator assist grips provide an easy to grip hand hold for stability when entering the truck—a function eased with a lowered and enlarged first step. Optional mini-lever hydraulic controls provide easy to use electronic controls along with a three-way adjustable armrest to enhance operator comfort and productivity.

The 8-Series trucks offer Toyota’s exclusive System of Active Stability (SAS), which helps reduce the likelihood of lateral and longitudinal tipovers. When the SAS system detects instability, its advanced sensors simultaneously signal and engage the appropriate controller. The Active Control Rear Stabilizer System and the Active Mast Function Controller System team to add truck stability and help reduce the likelihood of a lateral overturn and decrease the chance of spilling a load or tipping the lift truck forward or backward. A vehicle travel speed control system has been incorporated as standard equipment, which helps regulate the lift truck’s maximum travel speed to meet a wide range of operator skill levels.

A variety of features combine to provide operators optimal visibility. Dash-mounted digital displays, along with low profile cowl and sloped dashboard, provide an unobstructed view of the forktips in any position. Strategic overhead guard bar placement provides ideal visibility when positioning forks and handling higher placed loads. A wide-view rear overhead guard opening with high mount rear lights integrated into the overhead guard provides operators the view they require when driving in reverse.

Powering the 8-Series are the 1KD diesel and 1FS gasoline/LPG engines, designed for industrial operation and built by Toyota Industries Corp. (TICO). These four-cylinder models feature the latest electronic fuel injection systems with Controller Area Network (CAN-BUS) technology to deliver substantial improvements over the previous six-cylinder engines they replace.

Owing to new engineering advancements, Toyota’s 8-Series engines provide the same or greater horsepower and torque as an inline six-cylinder engine, while achieving greater fuel savings. On average, 8-Series models running the 1KD diesel engine reduce fuel consumption by 30 percent compared to prior models.

To ensure optimal performance, both engines underwent two years of design, calibration and rigorous testing, including 10,000-hour test cycles on the dynamometer. With common rail fuel injection, the 1KD 3.0 liter engine equips 8-Series large capacity pneumatic lift truck models with quicker throttle response and precise control of the amount of diesel being injected and burned for greater efficiency.

To meet today’s emissions requirements, the 1KD fuel injection system works in conjunction with an intercooled, variable nozzle turbocharger and a Diesel Oxidation Catalyst, minimizing emissions and particulate matter to levels meeting the Environmental Protection Agency Tier IV Final emissions standards. — Toyota Material Handling U.S.A., Columbus, Ind., 800/226-0009; 

1KD Diesel Engine: Tier IV sans DPF
Common rail fuel injection, coupled with exhaust treatment components similar to EPA 2010-compliant diesel engines for on-highway trucks—excepting diesel particulate filters—have positioned the Toyota 1KD engine for EPA Tier IV certification. In addition to the common rail fuel injection, Toyota Material Handling credits the four-cylinder engine’s fuel efficiency gains over predecessor lift trucks’ six-cylinder power packages to:
• A standard Load Sensing Power Steering system for precise maneuverability and reduced engine power loads, operating only when there is demand from the driver;
• An Economy or “Eco” Mode to help improve truck fuel efficiency over the course of the work day with minimum power reduction by optimizing the engine’s performance curve to work conditions; and,
• A programmable Auto Engine Off feature that automatically powers down the lift truck after a user programmable preset amount of time to save both fuel and unnecessary wear and tear on the engine.