Toyota BT Levio LWE140 Product Manual Download

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Product guide – BT Levio W-series

Options

Battery change from the side

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Battery change table

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Extra battery cables

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Battery change cable

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Built-in charger

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Spacer for long side pallet handling

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Truck log systems

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Integrated E-bar with optional accessories

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Turtle button

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Operator platform

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Load support

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Metal battery cover

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Rubber border

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Feature

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Benefit

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Hydraulic oil for low temperatures

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Greasable stainless steel axles

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Appendix

Environmental work within BT

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Focus on quality within BT

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Certificates

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Summary of Contents for BT Levio LWE140

Page 1: ...www toyota forklifts eu Product guide W series LWE140 LWE160 LWE180 LWE200 LWE250...

Page 2: ...250 PT 840aa Document revision history Edition date Changes April 2008 Next generation Low lifters February 2011 Technical updates August 2011 New family and series name Januare 2012 Technical updates...

Page 3: ...mation 9 BT Levio W series Low lifter Walkie Electric 9 LWE140 11 LWE160 11 LWE180 12 LWE200 12 LWE250 13 Applications 15 Industry 16 Warehouses distribution centres 16 Shops supermarkets 17 Which tru...

Page 4: ...l 39 Electronic components 42 Cover 43 Castor wheels 45 Fork carriage 47 Battery compartments batteries and chargers 49 Technical information 53 Dimensions and performance figures 53 Ast Aisle width r...

Page 5: ...or long side pallet handling 68 Truck log systems 69 Integrated E bar with optional accessories 71 Turtle button 72 Operator platform 73 Load support 75 Metal battery cover 75 Rubber border 76 Feature...

Page 6: ...Product guide BT Levio W series 6...

Page 7: ...w of all truck versions in the series Applications This chapter describes typical customers and truck applications Sales arguments Results from market research carried out during fall 2007 are present...

Page 8: ...Product guide BT Levio W series 8...

Page 9: ...istics can be programmed and adapted to individual operator preferences The design with rounded body contours together with a 5 point wheel configuration ensures operator comfort and safety The placem...

Page 10: ...view of battery sizes and some of the usable battery dimensions that apply to the different truck versions in the LWE series LWE140 LWE160 LWE180 LWE200 LWE250 Battery Small1 150 Ah X X Medium 2 225 A...

Page 11: ...battery compartment only 150 Ah battery l2 measurement 481 mm Ideal for applications in smaller shops and warehouses LWE160 BT Castor link 156 mm narrow fork carriage Chassis width 726 mm Small or med...

Page 12: ...ns in warehouses and distribution centres LWE200 BT Castor link 180 mm standard fork carriage Chassis width 726 mm Medium or large standard battery compartment 225 300 Ah battery Large battery with ba...

Page 13: ...d fork carriage Reinforced fork carriage Chassis width 726 mm Medium or large standard battery com partment 225 300 Ah battery Large battery with battery towards the side 260 Ah battery l2 measurement...

Page 14: ...Product range information Product guide BT Levio W series 14...

Page 15: ...wide range of applications from distribution centres to small warehouses and shops puts big demands on the trucks To meet different customer requirements the LWE trucks feature high performance and ea...

Page 16: ...eral LWE truck versions can be used especially thanks to the high quality that guarantees the truck is always available when needed For heavy loads an LWE250 truck is an excellent choice Warehouses di...

Page 17: ...he LWE trucks feature simple operation and they have a programmable switch off timer If the operator leaves the truck unattended it will switch off after the programmed time from one minute to four ho...

Page 18: ...el is suited for a given application Load carrier and load centre distance Capacity Usage intensity Travel distances Aisle widths Ramps slopes Floor conditions It is also recommended to explore enviro...

Page 19: ...oints to three important criteria for this kind of truck Simplicity Safety Durability These three key criteria are interconnected A truck that is easy to use is also a safe truck A safe truck cuts dow...

Page 20: ...ller arm has two ben efits The truck is easy to operate even by inex perienced operators while the steering angle is the same in both directions enabling easy truck handling in confined areas The desi...

Page 21: ...oods are being transported or being placed for storage Control Feature The trucks are equipped with the BT Pow erdrive system offering quick accelera tion and braking Benefit BT Powerdrive provides qu...

Page 22: ...or always has safe distance to the truck This reduces the risk of foot injuries while the low floor clearance provides added protection in case the op erator should get too close to the truck Since th...

Page 23: ...ng to extend the service life and eliminate the need for lubrication AC motor that does not move with the drive wheel carbon brushes that wear out and cables that twist have been eliminated The cable...

Page 24: ...ed with two screws The number of components has been consider ably reduced The truck is made from standard modules that are shared with several other truck models e g SWE Fixtures are designed to enab...

Page 25: ...the walkie versions while the other is designed for the platform versions with the op erator riding onboard Both versions use BT s ergonomic handles On the LWE140 and LWE160 the handle is slightly sma...

Page 26: ...a PIN code Up to 100 different PIN codes can be used to start the truck It is possible to either open up blocks using preselected PIN codes or user defined blocks can be programmed with the help of a...

Page 27: ...ks feature a tiller arm optimised for manoeuvrability and optimum safe distance to the operator s feet It is centrally placed and mounted in a low position Benefit Thanks to the long tiller arm the op...

Page 28: ...pinched between the truck and a wall or other obstacle Feature A spiral shaped cable connects in the lower part of the tiller arm Benefit Thanks to the spiral shaped design the cable is not bent thus...

Page 29: ...is indicator lights The param eter list can then be verified in the display D Battery indicator when this indicator lights battery capacity is displayed as a percentage of full capacity 100 equals a f...

Page 30: ...rs and storage compartments Two different types of battery covers are available the standard ABS battery cover and a metal battery cover The ABS covers are available with three different stor age comp...

Page 31: ...th PIN 3 truck characteristics are set to maxi mum performance See all parameters in the parameter table Automatic back up All parameters are stored in the logic card and the motor controller Feature...

Page 32: ...red key on the keypad or the ID unit The following table lists available operator parameters Parameters No Parameter type Unit Min Max Slow value Std value Max Perf Notes 4 Acceleration 10 100 60 80...

Page 33: ...irm service parameters however it is not possible to make changes in the register An example of service parameters are service interval time interval when the truck signals service is required automat...

Page 34: ...p speed This feature switches truck travel to inching speed and permits truck travel with the tiller arm in the upright position It is activated by quickly mov ing the travel direction selector R two...

Page 35: ...e released In this case the motor controller ensures the truck is kept stationary Benefit It is always safe to start the trucks in inclinations The operator does not risk having the truck roll over hi...

Page 36: ...neration of kinetic energy makes the truck more energy efficient Motor and power pack The LWE trucks feature BT Powerdrive and use AC drive motors and DC pump motors The reason for using a DC motor fo...

Page 37: ...mpact truck design since the space usually used to allow cable twisting has been eliminated Feature Gear box oil is synthetic with the following features Excellent lubrication properties even at low t...

Page 38: ...ility and reduced downtime thanks to the reduced number of moving parts and wear points Feature CAN bus communication digital communication between different system parts Benefit Provides quick reliab...

Page 39: ...ade depending on intended load usage intensity and the application 1 Vulkollan Feature Vulkollan is a hard wearing wheel rated for very high loads It is an ideal choice in heavy duty applications Bene...

Page 40: ...ure This wheel has quartz sand mixed in the tread causing a sand paper effect that results in slight wear on the surfaces on which the truck travels Benefit Clear benefits are the high loads it can ha...

Page 41: ...e central placement of the drive wheel the machine does not pitch when the wheel regains its grip after spin ning e g on wet floors and ramps With a drive wheel placed off centre consid erable lateral...

Page 42: ...lts Benefit Communication is safe and reliable even in severe use Feature The truck models in the LWE and SWE series share many common cables and components Benefit This simplifies service procedures...

Page 43: ...eeds up service interventions The resistant design reduces downtime and eliminates the need for unnecessary repairs Chassis The chassis width on all LWE trucks is identical The chassis is reinforced a...

Page 44: ...most needed thus protecting the various truck func tions Feature Floor clearance i e the distance between the floor and bumper is 35 mm Benefit This short distance protects the operator s feet from b...

Page 45: ...LWE140 LWE160 LWE180 LWE200 LWE200 with the optional operator platform and LWE250 have unique variants of the BT Castor Link system called BT Power Link This system is a new active hydraulic castor wh...

Page 46: ...wheel for example loses its footing outside a ramp edge there is no risk the wheel suspension assembly will be knocked apart when the wheel regains its footing This is because the wheel that has lost...

Page 47: ...dium intensive applications even in confined areas where good manoeuvrability is demanded Available on LWE140 LWE160 Feature Standard fork carriage with 180 mm wide forks Benefit The standard fork car...

Page 48: ...ct opti mally with the bushings Feature Zinc coated axles combined with nylon bushings only on forks wheels Benefit This is a cost effective proven technology for low and medium applications The fork...

Page 49: ...attery is required If a low capacity battery is selected for intensive applications battery capacity will be insufficient To obtain maximum usefulness from the battery it is important to select a char...

Page 50: ...and ventilated batteries GEL batter ies The valve regulated batteries are manufactured by Hawker GEL Evolution and are available in medium and large sizes Feature The customer can choose between diffe...

Page 51: ...or further instructions on maintenance of the bat tery and charger as well as change of battery see Technical information Charger A wide choice of battery chargers is available on the market These cha...

Page 52: ...ers are cost effec tive HF chargers are not as sensitive to fluctuations in the line voltage and they are able to carefully control the charging process and as a result the charging dura tion Benefit...

Page 53: ...rk to the fork wheel centre For trucks with bogie wheels it is measured from back of fork to fork bogie wheel centre Usually this measurement is available in the Product information l measurement The...

Page 54: ...g side handling of pallets With incorrect u and T measurements the fork wheels will not fit between the pallet legs As a result the truck will crush the pallet during lift operation p measurement The...

Page 55: ...44 1220 320 900 1019 964 1370 285 1085 1204 1149 1450 285 1165 1284 1229 1520 285 1235 1354 1299 LWE180 200 250 FI u T X down Fl u 116 X up Fl u 59 800 310 490 606 549 850 310 540 656 599 900 310 590...

Page 56: ...138 138 90 90 90 520 208 208 160 160 160 536 224 224 176 176 176 550 238 238 190 190 190 570 258 258 210 210 210 685 373 373 325 325 325 h13 measurement height of fork in lowered position h23 measure...

Page 57: ...he space required by the truck to pick a pallet from a pallet rack reverse out in the aisle turn and proceed down the aisle The formula according to VDI used to calculate the aisle width requirement i...

Page 58: ...shortside handling large 1496 1948 1000x1200 longside handling large 1496 1998 800x1200 shortside handling Truck Battery comp Wa Ast Aisle width for pallets LWE200 medium 1447 1899 1000x1200 longside...

Page 59: ...Calculating Ast according to the standard LWE range The values are from the Product information sheet for LWE200 Standard Ast 1447 1200 898 2 100 Ast 1949 Length of pallet must be substituted by tota...

Page 60: ...tic load capacity 1500 kg Other outer dimensions available 600 800 mm Chep pallet UK version Outer dimensions 1000 1200 mm Pallet height 162 mm Height fork entries 120 mm short side handling 95 mm lon...

Page 61: ...and whether they will be handled long side or short side Handling of roll containers 700 mm x 800 mm L x W Recommended fork specifications Number of roll containers FL 1450 mm 2 FL 2150 mm 3 Applicat...

Page 62: ...in batt weight kg Max batt weight kg Capacity Ah Volt V Size L W H mm Medium 180 235 225 24 645 x 196 x 570 Large 230 285 300 24 645 x 245 x 570 LWE200 Batt compartment Min batt weight kg Max batt wei...

Page 63: ...to 70 to be compared with 80 for freely ventilated batteries Ambient temperature for battery operation is 5 C to 35 C For uninterrupted battery warranty coverage only charge with Hawker ap proved char...

Page 64: ...Technical information Product guide BT Levio W series 64...

Page 65: ...eplacement only for trucks with a large bat tery compartment Not available for LWE140 LWE160 and LWE180 Feature The battery rests on a roller bed inside the battery compartment Benefit Changing the ba...

Page 66: ...battery cables If several batteries are used optional battery ca bles can be ordered Feature Each battery can then have its own cable always fixed to the battery Benefit Battery replacement is even m...

Page 67: ...ter display During charging dash es blink to indicate charging progress When charging is complete the character display in dicates the number of Ah charged into the bat tery Benefit It is easy to dete...

Page 68: ...res proper ventila tion during charging Feature The number of Ah charged into the battery during the past 50 charging instances can be verified For more information see the service manual Benefit It i...

Page 69: ...nefits to help us operate more efficiently Note The system can be used without Movex update but this requires a large amount of manual data updating Further information about Toyota I site is availabl...

Page 70: ...are three possible behaviours of the truck when a collision is recorded The truck continues to operate as usual The truck switches to turtle mode to return to normal operation the truck must be restar...

Page 71: ...unted with special mounting brackets designed for the E bar Feature The mounting brackets can be used on all BT trucks fitted with an E bar They are easy to in stall and just as easy to remove Benefit...

Page 72: ...button is pressed once the truck enters the turtle mode and travels at reduced speed When the button is pressed once more the truck returns to the standard speed Benefit It is easy to activate and di...

Page 73: ...n the platform is suspended 610 mm above ground while the chassis has been designed to offer sufficient space for the feet behind the plat form Benefit It is easy to lower the platform with the foot t...

Page 74: ...is secured to a frame with rounded corners Benefit The frame offers numerous benefits In case of collisions it distributes the force of impact evenly to protect the truck chassis The rounded corners e...

Page 75: ...ad support is bolted onto the fork back Benefit The load support can easily be post fitted Metal battery cover The metal battery cover is available for all BT Levio W series models and all bat tery co...

Page 76: ...d with the optional operator platform on LWE200 Feature A rubber border is available as an alternative to the standard steel border Benefit The climbing ability of the truck is improved and it is poss...

Page 77: ...l impact of the trucks is focused on The trucks contents of substances of concern to the environment are analysed In this area we are enforcing environmental demands on our suppliers Environmental car...

Page 78: ...eamwork Toyota stimulates personal and professional growth shares opportunities for de velopment and maximises individual and team performance Toyota Production System TPS is a production philosophy b...

Page 79: ...sts As a complement to calculations structural tests as well as life time tests are performed Apart from the functional testing and control made on all products before delivery product quality is cont...

Page 80: ...Appendix Product guide BT Levio W series 80 Certificates...

Page 81: ...Appendix Product guide BT Levio W series 81...

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