1—Product Development Exploiting Combined Strengths of Diverse Businesses—

Development of New Lift Trucks Fitted withEngines Having Significantly Greater
Environmental Performance
As economic activities expand, flows of commodities increase and become more active. Active, yet smoothcommodity flows support people’s daily life.
Smooth commodity flows are ensured by lift trucks, for which Toyota Industries enjoys the world-leading
market share* in unit sales.
In October 2013, we released new internal-combustion lift trucks in North America. This special feature sheds
a spotlight on how we leveraged the combined strengths of our diverse businesses in developing these models.
* Survey by Toyota Industries Corporation

Continued Growth in Lift Truck Market
Since commencing production of lift trucks in 1956, wehave been providing optimum products to customers andresponding to their needs through our enhanced sales andservice networks. In the fields of electric-powered andinternal-combustion lift trucks, we offer an extensive lineupof products ranging from small to large models and currently
hold the world-leading market share in unit sales.
After showing a drastic decline following the global
recession triggered by the collapse of Lehman Brothers in2008, the global lift truck market returned to a growth pathin line with an upswing in the global economy, reaching alevel of 1 million units in 2013. Going forward, a continued
recovery of the global economy and the subsequent rise inlogistics volume will add greater importance to the role thatlift trucks play in supporting commodity flows.
n Global Lift Truck Market and Toyota Industries’ Unit Sales(Thousandunits)

Global lift truck market (CY)

Toyota Industries’ unit sales (FY)
(Thousandunits)
250

800

200600150

400

10020050

Global lift truck market

1,0000(CY/FY)

2007

2008

2009
Japan

2010

2011

2012

North America

2013

Internal-combustion lift trucks with capacities of 3.5 to
8.0 tons are one of the core groups of products we offer inthe field of lift trucks and have been used by customers insuch industries as paper, transportation and lumber for avariety of manufacturing and logistics activities.
Against this background, we undertook efforts to greatly
enhance our product appeal, including newly developedengines, under the key concept of “Attain the Industry’sTop-Level Environmental Performance” and implemented
a model change starting from North America in 2013.

Development of Lift Trucks with Even
Greater Product Appeal
The new lift trucks are fitted with our newly developed
industrial engines that offer improved environmental
performance in the form of considerably higher fuelefficiency. Other contributing factors to improved fuelefficiency are modifications made to the drive andhydraulic systems.
We also added changes to the truck body in an effort toenhance overall performance. We reviewed the functioningof a mast, which supports the lifting and lowering of a fork
carrying cargo, and redesigned its shape. The result wasexcellent forward visibility, which in turn contributed toensuring enhanced workability and safety during operation.
We also used our ingenuity in the rearrangement of thespace surrounding the operator’s seat and the shape ofcabin openings, thus successfully improving operator
comfort and accessibility.

02014(Plan)

EuropeToyota Industries’ unit sales

Special Feature

Others

CY: calendar year ended Dec. 31; FY: fiscal year ended March 31 of the following year
(Survey by Toyota Industries Corporation)

Growing Need for Greater Environmental
Performance in Internal-Combustion Lift
TrucksDemand for electric lift trucks is growing among customers
handling materials in such indoor logistics sites as
warehouses and plants. Demand for powerful internalcombustion lift trucks, on the other hand, still remains
strong among customers operating outdoors or handlingheavy loads.
Recently, environmental awareness has been growing ona global scale. Coupled with efforts in various industries toreduce logistics costs, internal-combustion lift trucks are
now required to offer greater fuel efficiency and passincreasingly rigorous emission standards, which have been
applied to lift trucks and other materials handling equipment
by a number of countries.
Since starting the development of internal-combustion
lift trucks about 60 years ago, we have been constantly
seeking to enhance the appeal of our products in the areasof functionality, safety and reliability as well as in terms ofenvironmental performance, including fuel efficiency.

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Toyota Industries Report 2014

Redesigned mastMoreover, we divided the lift truck body into six modules,
including left and right frames, cabin (operator’s seat) andpowertrain (drive system). This will enable us to add newmodels or change specifications more quickly in the future,
which we hope will lead to a shorter development period.

Developing Industrial Engines Leveraging
Years of Experience and via Collaboration
among Business Divisions
Our newly developed industrial engines that featuresignificantly higher environmental performance were the key
to success in developing these new lift trucks.
The Materials Handling Equipment Division and theEngine Division have been closely collaborating in the17Engines Featuring Significantly Improved
Environmental Performancedevelopment of lift truck engines. By quickly and accurately
capturing the needs of lift truck customers and reflecting
these needs in engine development, the two businessdivisions are efficiently creating engines that are ideal
for lift trucks.
Since launching production of engines in 1953, we haveproduced a variety of engines for automobiles as well as for
lift trucks and other materials handling equipment. Currently,
we manufacture automobile engines, including KD diesel
engines that are installed in the Innovative International
Multi-purpose Vehicle (IMV) series of Toyota Motor
Corporation (TMC); VD diesel engines fitted mainly in theLand Cruiser; AR gasoline engines primarily for the RAV4;
and industrial engines, including Y gas/gasoline engines.
In addition, we also have been playing a major role inthe development of diesel engines and accumulating
technology and know-how concerning automobile andindustrial engines.

Our newly developed Toyota 1KD industrial diesel engine
offers 23%*1 lower fuel consumption. It also features 43%*2
downsized displacement compared with the current model,
enabling easier mounting on lift trucks. For the 1KD dieselengine, an internally developed turbocharger greatly
contributed to lower fuel consumption and downsized
displacement and allowed us to clear emission standards
without relying on diesel particulate filters (DPF) that are
generally used to remove particulate matter (PM).

air, we applied our compression and machining technologies
that we have cultivated in the field of car air-conditioning
compressors. By utilizing a range of technologies and knowhow accumulated in other business divisions, we were able
to develop a more durable and compact turbocharger.
*1: Rated fuel consumption compared with the previous model (15Z, 280 g/kWh)*2: Compared with the previous model (15Z, 5,204 cc)

Further Accelerating Development of Lift
Trucks by Drawing on Our Strengths Derived
from Diverse Businesses
Toyota 1KD
diesel engine

Enhancing Development of Industrial Engines
Turbocharger

While being able to remove PM, DPF must use fuel toburn PM accumulated in the filter in order to restore theirfiltering performance, the process of which may require
downtime of lift trucks. A structure without DPF eliminates
the need for this fuel and work procedures, thereby
contributing to greater fuel efficiency and better productivity.
Moreover, industrial engines need to operate for a longer
period of time in a more demanding environment comparedwith automobile engines and thus require a highly durable
turbocharger. To develop a component used to compress
Engine development

those for automobile engines will be enforced, and in
emerging countries, where emissions will become subject
to more stringent control. We aim to raise the competitiveedge of our industrial engines and extend their use fromlift trucks produced in-house to other industrial equipment
fields. Specifically, we will promote sales of our engines
for such industrial equipment as construction andagricultural machinery.

In 2013, we successively developed three industrial engine
models. Leveraging our years of experience and combined
strengths of our diverse businesses, these engines haveattained significantly higher environmental performance.
The Toyota 1KD diesel engine and Toyota 1FS gas/
gasoline engine are installed in 3.5- to 8.0-ton capacity
internal-combustion lift trucks that underwent a modelchange and were marketed in North America. The Toyota
1ZS diesel engine is fitted in 1.5- to 3.2-ton models.
We expect the need for more compact industrial engineswith cleaner emissions will grow both in developed
countries, where rigorous emission standards equivalent toThe 3.5- to 8.0-ton capacity internal-combustion lift trucks
incorporating our total strengths were released in October
2013 in North America. We will expand sales of thesemodels globally, first to Europe and then to Japan. We seek
to satisfy the diverse needs of customers by fine-tuning our
product lineup and specifications to the characteristics ofrespective markets.
In addition to the Engine Division and the Compressor
Division highlighted in this feature story, the Materials
Handling Equipment Division is facilitating collaboration in
the areas of foundry, one of the elemental technologies
associated with lift trucks, and electronics, which isclosely related to the development of electric lift trucks.
By capitalizing
on our strengths
generated bythese diverse
businesses, wewill continue tofocus on thedevelopmentof lift trucks
that capture
customer needs.
Event for dealers held in Chicago to announce therelease of new models(Survey by Toyota Industries Corporation)n Specifications of New Industrial Engines
DieselGas (LPG)/gasoline

Model

Toyota 1KD(Previous model)
15Z

Toyota 1ZS(Previous model)
3Z

Toyota 1FS(Previous model)
1FZ

Cylinder typeIn-line 4-cylinder

In-line 6-cylinder

In-line 3-cylinder

In-line 4-cylinder

In-line 4-cylinder

In-line 6-cylinder

Displacement

43% smaller

5,204 cc

48% smaller

3,469 cc

18% smaller

4,476 cc

55 kW (2,200 rpm)

55 kW (2,000 rpm)

41 kW (2,200 rpm)

42 kW (2,200 rpm)

66 kW (2,550 rpm)*5

63 kW (2,350 rpm)*5

300 Nm (1,200-1,500 rpm) 275 Nm (1,800 rpm)

200 Nm (1,600 rpm)

200 Nm (1,600 rpm) 290 Nm (1,200-1,400 rpm)* 294 Nm (1,200 rpm)*5

2,982 ccthan the previous model

Maximum
output*3
Maximum
torque*3
Fuelconsumption*3 *4

215 g/kWh

23% lower*3: Values provided for reference purpose only

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Toyota Industries Report 2014

than the previous model

280 g/kWhthan the previous model

Major
applications

1,795 cc

3,685 ccthan the previous model

221 g/kWh

20% lower

than the previous model

5276 g/kWh

233 g/kWh

10% lower

259 g/kWhthan the previous model

Lift trucks, construction equipment, agricultural machinery, etc.
*4: Rated fuel consumption*5: Using liquefied petroleum gas (LPG)

19