Toyota BT Levio W Series User manual

www.toyota-forklifts.eu
Product guide
W-series
LWE140
LWE160
LWE180
LWE200
LWE250

This product guide applies to:
Model F code TD code
LWE140 PT 838aa
LWE160 PT 838ab
LWE180 PT 838ac
LWE200 PT 839aa
LWE250 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
Part number: 749851-040
Copyright BT
Edition: January, 2012
BT
Information and Training Services
SE-595 81 Mjölby
Sweden

Product guide – BT Levio W-series 3
Contents
Reading instructions 7
Product range information 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 truck for which application? …………………………………………18
Sales arguments 19
Simplicity ………………………………………………………………20
Safety …………………………………………………………………22
Durability ……………………………………………………………23

Product guide – BT Levio W-series
4
Product details 25
Operator environment ……………………………………………………25
Battery covers and storage compartments …………………………………30
Driving features/programming the truck ……………………………………31
Motor and power pack …………………………………………………36
Drive wheel ……………………………………………………………39
Electronic components …………………………………………………42
Cover …………………………………………………………………43
Castor wheels …………………………………………………………45
Fork carriage …………………………………………………………47
Battery compartments, batteries and chargers ………………………………49
Technical information 53
Dimensions and performance gures ………………………………………53
Ast – Aisle width requirement ……………………………………………57
Aisle width requirements …………………………………………………58
Pallets and pallet sizes …………………………………………………60
Choosing the optimal fork specication ……………………………………61
Application for different fork lengths ………………………………………61
Battery weights …………………………………………………………62
Battery and charger ……………………………………………………63

Product guide – BT Levio W-series 5
Options 65
Battery change from the side ……………………………………………65
Battery change table ……………………………………………………66
Extra battery cables ……………………………………………………66
Battery change cable ……………………………………………………66
Built-in charger …………………………………………………………67
Spacer for 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 ………………………………………………………………76
Benet ………………………………………………………………76
Hydraulic oil for low temperatures …………………………………………76
Greasable stainless steel axles ……………………………………………76
Appendix 77
Environmental work within BT ……………………………………………77
Focus on quality within BT ………………………………………………78
Certicates ……………………………………………………………80

Product guide – BT Levio W-series
6

Product guide – BT Levio W-series 7
Reading instructions
This product guide is designed as a point of reference. To facilitate searching for
specic features, it has an index at the back. In some cases, information is avail-
able in two different chapters. This applies especially to the Sales arguments and
Product details chapters describing the various features and benets of the truck.
To determine which chapter provides the desired information, please use the fol-
lowing content descriptions.
The various chapters of this product guide cover the following:
●●Product●range●information: Provides a general overview 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 presented here together with truck features and benets supporting the sales
arguments.
●●Product●details: This chapter offers detailed descriptions of truck features and
truck components. It also includes a list of features and benets.
●●Technical●information: This chapter presents capacity charts, load carriers, bat-
tery weights, x measurements, etc.
●●Options: This is a list of truck options together with a description of their fea-
tures and benets.
●●Appendix: Contains an environmental declaration, a description of environmen-
tal work and quality commitment within BT as well as a copy of the company's
ISO certication.

Product guide – BT Levio W-series
8

Product range information
Product guide – BT Levio W-series 9
Product range information
BT Levio W-series (Low-lifter Walkie Electric)
BT Levio W-series without platform is a complete low-lifter series for walkie
applications. These machines are mainly used where space is limited and travel
distances are relatively short. All models have a maximum speed of 6 km/h.
LWE200 can, as an option, be equipped with operator platform. This truck is pref-
erably used were travel distances are a bit longer and the operator wants to have the
comfort of a stand on platform. For more heavy duty applications were the truck is
used continuously in a multi shift operation the recommendation is to use a truck
from our LPE range.
The LWE series is built on a modular concept where a large number of compo-
nents are common for all models. This simplies production and increases truck
performance reliability.
The LWE machines are compact, easy-to-use trucks with AC drive motors. The
trucks' drive characteristics can be programmed and adapted to individual operator
preferences. The design with rounded body contours together with a 5-point wheel
conguration ensures operator comfort and safety. The placement of the tiller arm
and controls on the handle provide excellent ergonomics for the operator.
The LWE series has two fork carriages. The 156 mm fork width on the narrow
fork carriage is provided on the LWE140 and LWE160. The other LWE versions
feature a standard fork carriage with a fork width of 180 mm. The fork carriage
on the LWE250 is reinforced to accommodate increased rated load capacity. The
LWE200 and LWE250 have larger drive and lift motors. All models are supplied
with a standard battery compartment. Moreover, the LWE200 and LWE250 can be
optionally tted with a large battery combined with a side roller bed solution.
Open-end and bottom-boarded pallets account for a large portion of the load car-
riers handled by low-lifters. Additionally, this truck series offers a variety of fork
and wheel congurations to accommodate various load carriers (e.g. pallets, roll
containers, half pallets, etc.).
The BT model codes can be used as a guide for choosing the right model for the

Product range information
Product guide – BT Levio W-series
10
intended application:
Type of truck Capacity Feature
LWE = Low-lifter Walkie Electrical 140 = 1400 kg
160 = 1600 kg
180 = 1800 kg
200 = 2000 kg
250 = 2500 kg
L = Low-lifter
W = Walkie
E = Electrical
The model code indicates rated truck capacity. Rated capacity indicates the load,
which the model with standard conguration can lift and transport.
The diagram below presents an overview of the models included in the LWE series.
The following table provides an overview 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
Small 1) 150 Ah X X
Medium 2) 225 Ah X X X X
Large 3) 300 Ah X X X
Large (sideways battery change) 260 Ah X X
Dimensions, mm
b1 chassis width 726 726 726 726 726
l2 chassis length 481 1) 481 1)/538 2) 538 2)/588 3) 538 2)/588 3) 538 2)/588 3)
Ast aisle width for pallets 800x1200 lengthways 1842 1) 18421)/1899 2) 1899 2)/1948 3) 1899 2)/1948 3) 1899 2)/19483)
Wa turning radius 1420 1) 1420 1)/14772) 1447 2)/1496 3) 14472)/1496 3) 1447 2)/1496 3)
l fork length 810-1520 810-1520 800-2350 800-2350 800-2350
1) small battery compartment
2) medium battery compartment
3) large battery compartment

Product range information
Product guide – BT Levio W-series 11
LWE140
● BT Castor link.
● 156 mm narrow fork carriage.
● Chassis width 726 mm.
● Small standard 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 medium standard battery
compartment, 150/225 Ah battery.
● l2 measurement 481/538 mm.
● Ideal for applications in shops, ware-
houses and distribution centres.

Product range information
Product guide – BT Levio W-series
12
LWE180
● BT Castor link.
● 180 mm standard fork carriage.
● Chassis width 726 mm.
● Medium or large standard battery com-
partment, 225/300 Ah battery.
● l2 measurement 538/588 mm.
● Ideal for applications 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 battery towards the
side, 260 Ah battery.
● l2 measurement 538/588 mm.
● Ideal for applications in warehouses
and distribution centres.
● Platform option with optimized tiller
arm for longer distances when the
driver want the comfort of a stand-on
platform.

Product range information
Product guide – BT Levio W-series 13
LWE250
● BT Castor link.
● 180 mm standard 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 538/588 mm.
● Ideal for applications where loads tend
to be heavier as in industrial applica-
tions.

Product range information
Product guide – BT Levio W-series
14

Applications
Product guide – BT Levio W-series 15
Applications
Walking
There is always an LWE truck version that is optimised for the application no
matter whether this involves loading/unloading of lorries, horizontal transport and/
or order picking. These trucks are typically used in warehouses/distribution cen-
tres, industrial applications and shops/supermarkets with short to medium transport
distances (aprox. up to 50m). The trucks are designed for indoor use with tempera-
tures not falling below 0°C, but they can also be used outdoors on loading docks
and lorries. With optional hydraulic oil for low temperatures, the trucks can be used
in -35°C.
The 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 ease of use.
Riding
LWE200 with platform is preferably used were travel distances are a bit longer
and the operator wants to have the comfort of a stand on platform. For more heavy
duty applications were the truck is used continuously in a multi shift operation the
recommendation is to use a truck from our LPE range.
Because of the wide range of applications from distribution centres and industrial
applications to small warehouses and shops, this puts big demands on the trucks.
To meet different customer requirements, the LWE trucks feature high perform-
ance and ease of use to support staff whose work duties are not limited to only
truck operation.

Applications
Product guide – BT Levio W-series
16
Industry
Industrial applications require trucks with a high
level of reliability. Goods must always be in the
right place when needed. An increasing trend at
many manufacturing companies is to reduce ware-
house surfaces and intensify incoming deliveries.
Although incoming deliveries may be frequent,
usage intensity in these kinds of applications is
lower compared to use in warehouses and distri-
bution centres. Nevertheless, the goods handled
are often quite heavy. For this type of application,
several 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/distribution centres
For operation in warehouses and distribution
hubs, high productivity is a key factor. Operators
are usually adept at truck operation and expect a
quick, exible truck with sturdy design. This is
exactly what the LWE trucks offer with the added
possibility to adapt operator settings to individual
experience.
In warehouses and distribution centres, trucks
are often used for horizontal transport, loading/
unloading and order picking. They are also used to
load/unload lorries and trailers outdoors on load-
ing docks and lorry beds.

Applications
Product guide – BT Levio W-series 17
Shops/supermarkets
In shops and supermarkets, the trucks are often operated by inexperienced staff, and
they may even be left unattended on shop oors among customers and children.
This environment requires an easy-to-use truck designed to prevent unauthorised
use. The 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 hours.
In shops and supermarkets, truck use is rarely intensive, however operators want
to use the trucks for many different applications, e.g. to unload goods from lorries,
transport goods on full, half or quarter pallets and even to handle roll containers.
The trucks are also used to pick up products on the shop oor.

Applications
Product guide – BT Levio W-series
18
Which truck for which application?
The following factors determine which model 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 environmental requirements and future plans,
for example to choose a truck that will not become obsolete when the company
expands.

Sales arguments
Product guide – BT Levio W-series 19
Sales arguments
In fall 2007, BT carried out market research with participation from 300 respond-
ents across Europe, all of them potential customers. The results from this survey
points 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 down on damaged goods and truck damage, resulting
in a durable truck with extended service life.
The main sales arguments for the three identied areas, simplicity, safety and du-
rability, are described in the remainder of this chapter.

Sales arguments
Product guide – BT Levio W-series
20
Simplicity
These trucks are regarded as a tool. The intention is that both experienced and in-
experienced operators should be able to use them. The following features make the
LWE series trucks easy to operate:
Manoeuvrability
Feature
● The LWE trucks has a 5-point wheel congura-
tion, i.e. ve wheels, and a centrally located tiller
arm.
● The tiller arm length is optimised for excellent
manoeuvrability.
Benet
● Central placement of the tiller arm has two ben-
ets: 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 conned areas.
● The design with ve wheels, with one in the
centre, provides superior truck stability even
when driving on ramps.
● Thanks to the length of the tiller arm, the operator has excellent control over
truck movements.
Feature
● The LWE series trucks boast a very short l2
measurement from 478 mm depending on the
conguration and selected battery.
● All corners are rounded.
Benet
● The truck is compact and easy to manoeuvre in
conned areas.
● Reduced risk that it will get caught by or knock into obstacles.