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Product guide

W-series

LWE140

LWE160

LWE180

LWE200

LWE250

www.toyota-forklifts.eu

• Page 1
  Product guide W-series LWE140 LWE160 LWE180 LWE200 LWE250 www.toyota-forklifts.eu…
• Page 2
  This product guide applies to: Model F code TD code LWE140 838aa LWE160 838ab LWE180 838ac LWE200 839aa LWE250 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…

• Page 3: Table Of Contents

  Contents Reading instructions Product range information BT Levio W-series (Low-lifter Walkie Electric) … … …… …… … …… … …… 9 LWE140 … ………… …… … …… … …… … …… …… … …… … …… 11 LWE160 … ………… … …… …… … …… … …… … …… …… … …… 11 LWE180 ……

• Page 4
  Product details Operator environment … ……… …… … …… … …… … …… …… … …… 25 Battery covers and storage compartments …… … …… …… … …… … …… 30 Driving features/programming the truck … …… … …… …… … …… … …… 31 Motor and power pack …………
• Page 5
  Options Battery change from the side … …… … …… … …… … …… …… … …… 65 Battery change table … … …… …… … …… … …… … …… …… … …… 66 Extra battery cables … … …… …… … …… … …… … …… …… … …… 66 Battery change cable ……
• Page 6
  Product guide – BT Levio W-series…
• Page 7
  Reading instructions This product guide is designed as a point of reference. To facilitate searching for specific 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 benefits of the truck.
• Page 8
  Product guide – BT Levio W-series…

• Page 9: Product Range Information

  Product range information 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.

• Page 10
  Product range information intended application: Type of truck Capacity Feature LWE = Low-lifter Walkie Electrical 140 = 1400 kg L = Low-lifter W = Walkie 160 = 1600 kg E = Electrical 180 = 1800 kg 200 = 2000 kg 250 = 2500 kg The model code indicates rated truck capacity.

• Page 11: Lwe140

  Product range information LWE140 ● BT Castor link. ● 156 mm narrow fork carriage. ● Chassis width 726 mm. ● Small standard battery compartment only, 150 Ah battery. ● l measurement 481 mm. ● Ideal for applications in smaller shops and warehouses.

• Page 12: Lwe180

  Product range information LWE180 ● BT Castor link. ● 180 mm standard fork carriage. ● Chassis width 726 mm. ● Medium or large standard battery com- partment, 225/300 Ah battery. ● l measurement 538/588 mm. ● Ideal for applications in warehouses and distribution centres.

• Page 13: Lwe250

  Product range information 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.

• Page 14
  Product range information Product guide – BT Levio W-series…

• Page 15: Applications

  Applications 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.

• Page 16: Industry

  Applications 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.

• Page 17: Shops/Supermarkets

  Applications Shops/supermarkets In shops and supermarkets, the trucks are often operated by inexperienced staff, and they may even be left unattended on shop floors 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.

• Page 18: Which Truck For Which Application

  Applications 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.

• Page 19: Sales Arguments

  Sales arguments 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: ●…

• Page 20: Simplicity

  Sales arguments 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 configura- tion, i.e.

• Page 21
  Sales arguments View Feature The LWE trucks have a well-arranged ex- ternal design with superior operator view thanks to: ● A compact truck body that is lower on the fork side. ● Optimum distance to the truck with the operator sufficiently close to the truck for an unobstructed view.

• Page 22: Safety

  Sales arguments Safety A safe truck prevents injuries and reduces costly damage to goods and the truck. The LWE series trucks come with a number of features that makes them safe in use. Operator safety Feature ● The distance to the operator’s feet is consider- able and floor clearance is 35 mm.

• Page 23: Durability

  Sales arguments Durability A truck that cannot be used costs money. On one hand the truck must always be available when needed in order for business to continue as usual and remain ef- ficient, while on the other hand service costs often represent a significant share of total truck costs during the truck’s life cycle.

• Page 24
  Sales arguments Benefit By designing for durability to eliminate causes of trouble, the following has been achieved: ● Unscheduled downtime that causes business interruptions has been reduced. ● Unnecessary repair costs have been reduced. ● Truck service life has been extended. Quick and easy service Feature In the design of the LWE trucks, a high level of serviceability was a key focus:…

• Page 25: Product Details

  Product details Product details Operator environment The LWE trucks are primarily designed for operators walking alongside the truck and not standing on a platform, however, the LWE200 can be ordered with optional platform. Tiller arm and controls There are two versions of the tiller arm for the LWE series. One is designed for the walkie versions while the other is designed for the platform versions with the op- erator riding onboard.

• Page 26
  Product details Feature All controls are within easy reach and not placed too close together. The truck and all truck opera- tions can be operated with a single hand, left or right, as preferred. Benefit All controls are within immediate reach to reduce the risk of repetitive strain injury while opening up the possibility of productivity gains thanks to improved efficiency.
• Page 27
  Product details Benefit No matter whether the truck is protected by a PIN code or ID unit: ● The truck can always be guarded against unauthorised use. ● Up to ten different operator settings can be stored in truck memory. Some companies prefer a physical key, in case an ID key, for truck access in order to keep track of who is using the trucks, especially in cases where external opera- tors need to temporarily use the truck, while others prefer access via PIN codes that…
• Page 28
  Product details Feature When upright, the arm remains within the truck profile. Benefit The tiller arm does not require any space when left in the upright position, a clear advantage in very tight spaces. Feature The tiller arm features safety reversing. When the safety reversing switch is pushed, the trucks stops and immediately reverses in the other direction.
• Page 29
  Product details Display The display shows battery status, total travel time and error messages. The display is also used to program operator parameters. Normal- ly, battery capacity is displayed as a percentage (%), but can when needed be replaced by error codes or operator parameters.

• Page 30: Battery Covers And Storage Compartments

  Product details Benefit ● The operator can quickly confirm whether something is wrong with the truck, and he can in some cases correct it by restarting the truck. ● If intervention by a service technician is required, he can be informed about what’s wrong with the truck before arriving on site.

• Page 31: Driving Features/Programming The Truck

  Product details Driving features/programming the truck The LWE trucks are highly manoeuvrable and offer indi- vidual setting options for the operators. Settings that the operator can change himself are called operator parame- ters. The trucks also have a machine register in which set- tings only can be changed by a service technician.

• Page 32
  Product details Operator parameters To reprogram operator-specific parameters (if the change is permitted), proceed as follows: ● Press the horn button and keep it pressed while starting the truck using either PIN code entry or the ID unit. ● Release the horn button when the display shows “P”. The parameter symbol on the display lights.
• Page 33
  Product details Feature It is possible to adapt the settings for speed, acceleration and braking characteris- tics to the operator’s level of experience and/or preferences. The truck can store up to ten different settings. Benefit By adapting the truck to the operator and/or the application, damage caused by in- experienced operators can be reduced while maximum productivity can be achieved with experienced operators.
• Page 34
  Product details Automatic switch-off For more information regarding automatic switch-off, see the Service manual. Feature A service technician can set the desired time in- terval for truck switch-off in case the truck is left unattended. This time can be set to either 4 h or in the range of 1-20 minutes in increments of one minute.
• Page 35
  Product details Brakes During normal travel, the motor is used to brake the truck, however, it also has an electromechanical parking brake which is applied whenever the truck is not in use. The parking brake can be released by to screws. See service manual for more information.

• Page 36: Motor And Power Pack

  Product details Feature When the speed control is released to the neutral position or when the travel direc- tion changes, the motor brake is automatically applied. Benefit This makes truck travel more gentle and reduces brake plate wear. Feature During normal truck travel when the motor is used to brake the truck, energy is regenerated and returned to the battery every time the truck brakes.

• Page 37
  Product details AC drive motor The size of the motor depends on the truck: ● The LWE140, LWE160 and LWE180 use 1.0 kW drive motors. ● The LWE200 and LWE250 use 1.5 kW drive motors. Feature The drive motor is permanentnly mounted, and the motor does not move when the drive wheel turns.
• Page 38
  Product details BT Powerdrive system The BT Powerdrive system on the LWE series is a unique combination of contact- less controls, CAN bus communication (CAN = Controller Area Network) and AC drive motor. Feature Contactless controls Benefit High reliability and reduced downtime thanks to the reduced number of moving parts and wear points.

• Page 39: Drive Wheel

  Product details Drive wheel The drive wheel diameter is 230 mm. The LWE models offer four different mate- rial types. Drive wheel material The choice of drive wheel is a matter of balancing price, road holding characteris- tics and load handling performance. Four different types of materials are available: Topthane, Vulkollan, Powerfriction and Vulkollan mixed with sand.

• Page 40
  Product details 3. Powerfriction Feature All models can be ordered with Powerfriction drive wheels. This is a non-marking material with high friction coefficient. Benefit Powerfriction provides excellent grip, even on moist surfaces, and has superior wear characteristics. It does not leave marks on floors. 4.
• Page 41
  Product details Drive wheel bracket All models feature fixed mounting of the drive wheel with suspended castor wheels. For details, please refer to Castor wheels and BT Castor link. Feature The LWE trucks have a 5-point wheel con- figuration with the drive wheel in the cen- tre.

• Page 42: Electronic Components

  Product details Electronic components A general design objective of the LWE series, was to use as few electric compo- nents and cables as possible, while remaining parts are optimally protected against dirt, humidity, impacts, etc. Feature MQS (Micro Quadlok System) terminals are used throughout.

• Page 43: Cover

  Product details Cover Feature The cover is made of a highly resistant ABS material and is secured with only two screws. Two different covers exist, one for the walkie models and one for trucks with the platform op- tion. Benefit The cover is easy to remove and provides easy access to truck components.

• Page 44
  Product details Feature The lower part of the frame is compression- moulded. Benefit The moulding makes the truck more rigid while it absorbs impacts in an area where it is most needed, thus protecting the various truck func- tions. Feature Floor clearance, i.e.

• Page 45: Castor Wheels

  Product details Castor wheels The castor wheels have a width of 50 mm. It is possible to select between Vulkollan and Polyurethane as castor wheel material. Depending on the application, the load on the wheel suspension is handled differently. 3 different types of BT Castor Link are available, but they all rely on the same basic principle.

• Page 46
  Product details Feature When the truck turns or passes a bump, pressure increases on one castor wheel as a result of compression of the spring. Thanks to the torsion tube, the other spring will compress by an identical amount. Benefit The truck remains stable and will never start to rock and travel like a ‘walking duck’, a classic phenomenon when spring forces do not interact.

• Page 47: Fork Carriage

  Product details Fork carriage As far as the fork carriage is concerned, all bushings and axles, both classic prob- lem sources, have been improved. This chapter describes these parts together with the forks and fork wheels. Two fork carriages are used, narrow and standard. Feature Narrow fork carriage with 156 mm wide forks.

• Page 48
  Product details Axles and bushings Because bushings and axles are highly vulnerable parts, new high-quality materials have been developed for the LWE and SWE truck series. The results from truck life cycle tests have been very positive. Feature The bushings are made from Teflon-coated composite material. Benefit Teflon-coated composite bushings offer extended length of service and do not re- quire lubrication.

• Page 49: Battery Compartments, Batteries And Chargers

  Product details Battery compartments, batteries and chargers When selecting the battery, these aspects should be considered: ● Physical limitations of the battery compartment – information on battery com- partment sizes is available in the Technical information chapter. ● Minimum and maximum weight –- these weights are indicated in the Technical information chapter.

• Page 50
  Product details Feature It is possible to select a desired battery compartment size. On the larger models, battery replacement to the side is available as an option. Benefit The truck can be optimised for the intended application. For higher intensive ap- plications, lateral battery replacement is a recommended option.
• Page 51
  Product details Battery connector and charging To charge the battery, disconnect the battery connector and connect it to the battery charger. The battery connector should also be disconnected in the following situa- tions to cut the power supply: ● In the event of an accident. ●…
• Page 52
  Product details Feature Different types of chargers provide different characteristics: ● Conventional, unregulated chargers are sensitive to line voltage fluctuations. As a result, the charging duration can vary, however, these chargers 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.

• Page 53: Technical Information

  Technical information Technical information Dimensions and performance figures x measurement The x measurement is the distance back●of●fork●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 l measurement is the Total●fork●length. measurement The l measurement is the Truck●length●including●back●of●fork.

• Page 54
  Technical information u measurement The u measurement is the distance between fork● tip● and● the● wheel-fork● pivot● point. T measurement The measurement from●back●of●forks●to●the●wheel●fork●pivot●point is called the T measurement. The T measurement can be calculated with the formula: T = l -u As an example the u and T measurements are important for long side handling of pallets.
• Page 55
  Technical information Standard fork length tables LWE140/160 X down, Fl-u+119 X up, Fl-u+64 1000 1070 1120 1150 1200 1220 1019 1370 1085 1204 1149 1450 1165 1284 1229 1520 1235 1354 1299 LWE180/200/250 X down, Fl-u+116 X up, Fl-u+59 1000 1050 1070 1100…
• Page 56
  Technical information e, b and b measurements LWE140 LWE160 LWE180 LWE200 LWE250 measurement, height of fork in lowered position measurement, height of fork in raised position. e measurement, fork width measurement, width over forks The b measurement is referred to as the width●over●forks. This measurement must suit the pallets to be handled by the truck.

• Page 57: Aisle Width Requirement

  Technical information , turning radius The turning radius is the necessary Distance●to●turn●the●truck●around●a●virtual● point●referred●to●as●the●turning●centre with forks raised. The product informa- tion provides Wa measurements for all LWE truck versions. – Aisle width requirement The aisle width requirement can be described as the space required by the truck to pick a pallet from a pallet rack, reverse out in the aisle, turn and proceed down the aisle.

• Page 58: Aisle Width Requirements

  Technical information Aisle width requirements Truck Battery comp. Aisle width for pallets: LWE140 small 1420 1842 1000×1200 longside handling small 1420 1892 800×1200 shortside handling Truck Battery comp. Aisle width for pallets: LWE160 small 1420 1842 1000×1200 longside handling small 1420 1892 800×1200 shortside handling…

• Page 59
  Technical information Calculating A according to the standard, LWE range ● The values are from the Product information sheet for LWE200. Standard: A = 1447 + (1200 — 898) + 2×100 = 1949 Length of pallet must be substituted by total fork length Standard: A = 1447+ (1150 — 898) + 2×100 = 1899…

• Page 60: Pallets And Pallet Sizes

  Technical information Pallets and pallet sizes 1200 Euro pallet 382,5 382,5 ● Outer dimensions: 800 × 1200 mm ● Pallet height: 144 mm 227,5 227,5 ● Height, fork entries: 100 all four sides ● Corners: 45° ● Pallet weight: approximately 27 kg ●…

• Page 61: Choosing The Optimal Fork Specification

  Technical information Choosing the optimal fork specification When forks suited for a pallet or a specific roll container, these items should be considered: ● The b measurement must suit the pallet /roll container to enable positioning of the forks between the pallet legs or between the wheels of the roll container. Example: With Width over Forks 450 mm and Fork Width 180 mm, only 90 mm remains between the forks and the truck will not be able to handle Euro pallets or Chep pallets.

• Page 62: Battery Weights

  Technical information Battery weights LWE140 Batt. compartment Min. batt. weight kg Max. batt. weight kg Capacity Ah Volt V Size L*W*H mm Small 651 x 150 x 570 LWE160 Batt. compartment Min. batt. weight kg Max. batt. weight kg Capacity Ah Volt V Size L*W*H mm Small 651 x 150 x 570 Medium…

• Page 63: Battery And Charger

  Technical information Battery and charger Information on Hawker Evolution GEL batteries Hawker Evolution GEL batteries is the only type of valve-regulated batteries of- fered for the trucks in the LWE series. Please note the following if selecting a bat- tery of this type for the truck: ●…

• Page 64
  Technical information Product guide – BT Levio W-series…

• Page 65: Options

  Options Options To adapt the truck to customer preferences, a number of options are available. Battery change from the side Battery roller bed which enables lateral battery replacement (only for trucks with a large bat- tery compartment). Not available for LWE140, LWE160 and LWE180.

• Page 66: Battery Change Table

  Options Battery change table To facilitate battery change from the side, an exter- nal battery change table is also available. The height from the floor to the top of the rollers is adjustable. The battery change table measurments are 834 x 912 mm.

• Page 67: Built-In Charger

  Options Built-in charger When connected to 230 V, the charger has a capacity of 30 A.It is self-adjusting and can be used for voltages between 90 V and 255 V AC, 45 to 400 Hz. For voltages under 200 V, the output current will be reduced. Freely ventilated batteries up to 320 Ah and valve regulated batteries from 134 to 213 Ah can be charged.

• Page 68: Spacer For Long Side Pallet Handling

  Options Feature Any error codes generated by the battery charger are displayed on the display. Benefit This simplifies fault diagnosis if required. Feature When the built-in charger is used, it is not possible to charge the battery unless the battery cover is opened since the power cord needs to be pulled out from behind the cover.

• Page 69: Truck Log Systems

  Truck log systems Toyota I-site Toyota I-site is a truck log and fleet management system that provides possibili- ties to monitor truck usage and operator performance. Toyota I-site is offered a monthly fee basis where we provide a continual process of analysis and consul- tancy to customers and give them access to our knowledge and skills to help us build customer relations.

• Page 70
  Options If the shock sensor is included in the system, information about collisions and im- pacts can be viewed. By monitoring truck usage and operator performance, customers can improve op- erations and reduce cost. Access to different levels of information can be set for different users/functions in the company.

• Page 71: Integrated E-Bar With Optional Accessories

  Options Integrated E-bar with optional accessories All trucks in the LWE series, except for those with small battery compartment, can be fitted with an optional E-bar. This is BT’s standard solution for mounting a writing holder, plastic film holder, computer terminal, PC, scanner or other electronic equipment required onboard the truck.

• Page 72: Turtle Button

  Options Turtle button The turtle button allows temporary reduction of speed. The default setting for speed reduction is – 50 %, i.e. the travel speed will be reduced to 3 km/h. If necessary, this can be reprogrammed by a service technician. Feature When the turtle button is pressed once, the truck enters the turtle mode and travels at reduced speed.

• Page 73: Operator Platform

  Options Operator platform An operator platform is a useful option if the travel distances are a bit longer and the operator wants to have the comfort of a stand-on platform. The LWE series offers two different platform types, one with a rubber mat and automatic fold-up and a cold-store version with a checkered plate and also automatic fold-up.

• Page 74
  Options Feature The cold-store version of the platform uses a checkered plate. Benefit The checkered plate assures good friction even in cold stores and also in foodstuff applications where operators often wear wet or slippery shoes. Feature The platform is secured to a frame with rounded corners. Benefit The frame offers numerous benefits: ●…

• Page 75: Load Support

  Options Load support The optional load support is attached to the back of the forks and is available on all LWE trucks. Feature The load support has a height of 1500 mm (from the top of the forks). Benefit This added support protects the operator and goods.

• Page 76: Rubber Border

  Options Rubber border A rubber border is available for all BT Levio W-series models. The trucks can be ordered with a rubber border instead of the standard steel border to allow high gradient ramp handling ability. The rubber border is especially suited for applications with high thresholds, curbs and ramps with high gradients.

• Page 77: Appendix

  Appendix Appendix Environmental work within BT The BT trucks are produced at manufacturing sites where environmental issues are in focus. Waste management and reduction of hazardous chemicals used in production are natural parts of the everyday environmental work. We have been ISO 14001 certified since 1997, and in our continuous environmental work we put effort into reducing energy consumption on all levels, while we work with preven- tive actions to reduce pollution risks and the risk of biological danger.

• Page 78: Focus On Quality Within Bt

  Appendix Focus on quality within BT The Toyota Way is based on the Guiding Principles at Toyota. Its five core values express the beliefs and values used in the daily work: Challenge To maintain a long-term vision and meet all challenges with the courage and crea- tivity needed to realise that vision.

• Page 79
  Appendix Products and components are tested and evaluated throughout the development process, both in lab environments and field tests. 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 continuously monitored during manufacturing through welding audits on components and product audits on completed trucks.

• Page 80: Certificates

  Appendix Certificates Product guide – BT Levio W-series…

• Page 81
  Appendix Product guide – BT Levio W-series…

1. Manuals
2. Brands
3. Toyota Manuals
4. Forklifts
5. BT Levio W Series
6. Product manual

Quick Links

Product guide

W-series

LWE140

LWE160

LWE180

LWE200

LWE250

www.toyota-forklifts.eu

• Page 1
  Product guide W-series LWE140 LWE160 LWE180 LWE200 LWE250 www.toyota-forklifts.eu…
• Page 2
  This product guide applies to: Model F code TD code LWE140 838aa LWE160 838ab LWE180 838ac LWE200 839aa LWE250 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…

• Page 3: Table Of Contents

  Contents Reading instructions Product range information BT Levio W-series (Low-lifter Walkie Electric) … … …… …… … …… … …… 9 LWE140 … ………… …… … …… … …… … …… …… … …… … …… 11 LWE160 … ………… … …… …… … …… … …… … …… …… … …… 11 LWE180 ……

• Page 4
  Product details Operator environment … ……… …… … …… … …… … …… …… … …… 25 Battery covers and storage compartments …… … …… …… … …… … …… 30 Driving features/programming the truck … …… … …… …… … …… … …… 31 Motor and power pack …………
• Page 5
  Options Battery change from the side … …… … …… … …… … …… …… … …… 65 Battery change table … … …… …… … …… … …… … …… …… … …… 66 Extra battery cables … … …… …… … …… … …… … …… …… … …… 66 Battery change cable ……
• Page 6
  Product guide – BT Levio W-series…
• Page 7
  Reading instructions This product guide is designed as a point of reference. To facilitate searching for specific 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 benefits of the truck.
• Page 8
  Product guide – BT Levio W-series…

• Page 9: Product Range Information

  Product range information 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.

• Page 10
  Product range information intended application: Type of truck Capacity Feature LWE = Low-lifter Walkie Electrical 140 = 1400 kg L = Low-lifter W = Walkie 160 = 1600 kg E = Electrical 180 = 1800 kg 200 = 2000 kg 250 = 2500 kg The model code indicates rated truck capacity.

• Page 11: Lwe140

  Product range information LWE140 ● BT Castor link. ● 156 mm narrow fork carriage. ● Chassis width 726 mm. ● Small standard battery compartment only, 150 Ah battery. ● l measurement 481 mm. ● Ideal for applications in smaller shops and warehouses.

• Page 12: Lwe180

  Product range information LWE180 ● BT Castor link. ● 180 mm standard fork carriage. ● Chassis width 726 mm. ● Medium or large standard battery com- partment, 225/300 Ah battery. ● l measurement 538/588 mm. ● Ideal for applications in warehouses and distribution centres.

• Page 13: Lwe250

  Product range information 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.

• Page 14
  Product range information Product guide – BT Levio W-series…

• Page 15: Applications

  Applications 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.

• Page 16: Industry

  Applications 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.

• Page 17: Shops/Supermarkets

  Applications Shops/supermarkets In shops and supermarkets, the trucks are often operated by inexperienced staff, and they may even be left unattended on shop floors 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.

• Page 18: Which Truck For Which Application

  Applications 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.

• Page 19: Sales Arguments

  Sales arguments 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: ●…

• Page 20: Simplicity

  Sales arguments 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 configura- tion, i.e.

• Page 21
  Sales arguments View Feature The LWE trucks have a well-arranged ex- ternal design with superior operator view thanks to: ● A compact truck body that is lower on the fork side. ● Optimum distance to the truck with the operator sufficiently close to the truck for an unobstructed view.

• Page 22: Safety

  Sales arguments Safety A safe truck prevents injuries and reduces costly damage to goods and the truck. The LWE series trucks come with a number of features that makes them safe in use. Operator safety Feature ● The distance to the operator’s feet is consider- able and floor clearance is 35 mm.

• Page 23: Durability

  Sales arguments Durability A truck that cannot be used costs money. On one hand the truck must always be available when needed in order for business to continue as usual and remain ef- ficient, while on the other hand service costs often represent a significant share of total truck costs during the truck’s life cycle.

• Page 24
  Sales arguments Benefit By designing for durability to eliminate causes of trouble, the following has been achieved: ● Unscheduled downtime that causes business interruptions has been reduced. ● Unnecessary repair costs have been reduced. ● Truck service life has been extended. Quick and easy service Feature In the design of the LWE trucks, a high level of serviceability was a key focus:…

• Page 25: Product Details

  Product details Product details Operator environment The LWE trucks are primarily designed for operators walking alongside the truck and not standing on a platform, however, the LWE200 can be ordered with optional platform. Tiller arm and controls There are two versions of the tiller arm for the LWE series. One is designed for the walkie versions while the other is designed for the platform versions with the op- erator riding onboard.

• Page 26
  Product details Feature All controls are within easy reach and not placed too close together. The truck and all truck opera- tions can be operated with a single hand, left or right, as preferred. Benefit All controls are within immediate reach to reduce the risk of repetitive strain injury while opening up the possibility of productivity gains thanks to improved efficiency.
• Page 27
  Product details Benefit No matter whether the truck is protected by a PIN code or ID unit: ● The truck can always be guarded against unauthorised use. ● Up to ten different operator settings can be stored in truck memory. Some companies prefer a physical key, in case an ID key, for truck access in order to keep track of who is using the trucks, especially in cases where external opera- tors need to temporarily use the truck, while others prefer access via PIN codes that…
• Page 28
  Product details Feature When upright, the arm remains within the truck profile. Benefit The tiller arm does not require any space when left in the upright position, a clear advantage in very tight spaces. Feature The tiller arm features safety reversing. When the safety reversing switch is pushed, the trucks stops and immediately reverses in the other direction.
• Page 29
  Product details Display The display shows battery status, total travel time and error messages. The display is also used to program operator parameters. Normal- ly, battery capacity is displayed as a percentage (%), but can when needed be replaced by error codes or operator parameters.

• Page 30: Battery Covers And Storage Compartments

  Product details Benefit ● The operator can quickly confirm whether something is wrong with the truck, and he can in some cases correct it by restarting the truck. ● If intervention by a service technician is required, he can be informed about what’s wrong with the truck before arriving on site.

• Page 31: Driving Features/Programming The Truck

  Product details Driving features/programming the truck The LWE trucks are highly manoeuvrable and offer indi- vidual setting options for the operators. Settings that the operator can change himself are called operator parame- ters. The trucks also have a machine register in which set- tings only can be changed by a service technician.

• Page 32
  Product details Operator parameters To reprogram operator-specific parameters (if the change is permitted), proceed as follows: ● Press the horn button and keep it pressed while starting the truck using either PIN code entry or the ID unit. ● Release the horn button when the display shows “P”. The parameter symbol on the display lights.
• Page 33
  Product details Feature It is possible to adapt the settings for speed, acceleration and braking characteris- tics to the operator’s level of experience and/or preferences. The truck can store up to ten different settings. Benefit By adapting the truck to the operator and/or the application, damage caused by in- experienced operators can be reduced while maximum productivity can be achieved with experienced operators.
• Page 34
  Product details Automatic switch-off For more information regarding automatic switch-off, see the Service manual. Feature A service technician can set the desired time in- terval for truck switch-off in case the truck is left unattended. This time can be set to either 4 h or in the range of 1-20 minutes in increments of one minute.
• Page 35
  Product details Brakes During normal travel, the motor is used to brake the truck, however, it also has an electromechanical parking brake which is applied whenever the truck is not in use. The parking brake can be released by to screws. See service manual for more information.

• Page 36: Motor And Power Pack

  Product details Feature When the speed control is released to the neutral position or when the travel direc- tion changes, the motor brake is automatically applied. Benefit This makes truck travel more gentle and reduces brake plate wear. Feature During normal truck travel when the motor is used to brake the truck, energy is regenerated and returned to the battery every time the truck brakes.

• Page 37
  Product details AC drive motor The size of the motor depends on the truck: ● The LWE140, LWE160 and LWE180 use 1.0 kW drive motors. ● The LWE200 and LWE250 use 1.5 kW drive motors. Feature The drive motor is permanentnly mounted, and the motor does not move when the drive wheel turns.
• Page 38
  Product details BT Powerdrive system The BT Powerdrive system on the LWE series is a unique combination of contact- less controls, CAN bus communication (CAN = Controller Area Network) and AC drive motor. Feature Contactless controls Benefit High reliability and reduced downtime thanks to the reduced number of moving parts and wear points.

• Page 39: Drive Wheel

  Product details Drive wheel The drive wheel diameter is 230 mm. The LWE models offer four different mate- rial types. Drive wheel material The choice of drive wheel is a matter of balancing price, road holding characteris- tics and load handling performance. Four different types of materials are available: Topthane, Vulkollan, Powerfriction and Vulkollan mixed with sand.

• Page 40
  Product details 3. Powerfriction Feature All models can be ordered with Powerfriction drive wheels. This is a non-marking material with high friction coefficient. Benefit Powerfriction provides excellent grip, even on moist surfaces, and has superior wear characteristics. It does not leave marks on floors. 4.
• Page 41
  Product details Drive wheel bracket All models feature fixed mounting of the drive wheel with suspended castor wheels. For details, please refer to Castor wheels and BT Castor link. Feature The LWE trucks have a 5-point wheel con- figuration with the drive wheel in the cen- tre.

• Page 42: Electronic Components

  Product details Electronic components A general design objective of the LWE series, was to use as few electric compo- nents and cables as possible, while remaining parts are optimally protected against dirt, humidity, impacts, etc. Feature MQS (Micro Quadlok System) terminals are used throughout.

• Page 43: Cover

  Product details Cover Feature The cover is made of a highly resistant ABS material and is secured with only two screws. Two different covers exist, one for the walkie models and one for trucks with the platform op- tion. Benefit The cover is easy to remove and provides easy access to truck components.

• Page 44
  Product details Feature The lower part of the frame is compression- moulded. Benefit The moulding makes the truck more rigid while it absorbs impacts in an area where it is most needed, thus protecting the various truck func- tions. Feature Floor clearance, i.e.

• Page 45: Castor Wheels

  Product details Castor wheels The castor wheels have a width of 50 mm. It is possible to select between Vulkollan and Polyurethane as castor wheel material. Depending on the application, the load on the wheel suspension is handled differently. 3 different types of BT Castor Link are available, but they all rely on the same basic principle.

• Page 46
  Product details Feature When the truck turns or passes a bump, pressure increases on one castor wheel as a result of compression of the spring. Thanks to the torsion tube, the other spring will compress by an identical amount. Benefit The truck remains stable and will never start to rock and travel like a ‘walking duck’, a classic phenomenon when spring forces do not interact.

• Page 47: Fork Carriage

  Product details Fork carriage As far as the fork carriage is concerned, all bushings and axles, both classic prob- lem sources, have been improved. This chapter describes these parts together with the forks and fork wheels. Two fork carriages are used, narrow and standard. Feature Narrow fork carriage with 156 mm wide forks.

• Page 48
  Product details Axles and bushings Because bushings and axles are highly vulnerable parts, new high-quality materials have been developed for the LWE and SWE truck series. The results from truck life cycle tests have been very positive. Feature The bushings are made from Teflon-coated composite material. Benefit Teflon-coated composite bushings offer extended length of service and do not re- quire lubrication.

• Page 49: Battery Compartments, Batteries And Chargers

  Product details Battery compartments, batteries and chargers When selecting the battery, these aspects should be considered: ● Physical limitations of the battery compartment – information on battery com- partment sizes is available in the Technical information chapter. ● Minimum and maximum weight –- these weights are indicated in the Technical information chapter.

• Page 50
  Product details Feature It is possible to select a desired battery compartment size. On the larger models, battery replacement to the side is available as an option. Benefit The truck can be optimised for the intended application. For higher intensive ap- plications, lateral battery replacement is a recommended option.
• Page 51
  Product details Battery connector and charging To charge the battery, disconnect the battery connector and connect it to the battery charger. The battery connector should also be disconnected in the following situa- tions to cut the power supply: ● In the event of an accident. ●…
• Page 52
  Product details Feature Different types of chargers provide different characteristics: ● Conventional, unregulated chargers are sensitive to line voltage fluctuations. As a result, the charging duration can vary, however, these chargers 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.

• Page 53: Technical Information

  Technical information Technical information Dimensions and performance figures x measurement The x measurement is the distance back●of●fork●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 l measurement is the Total●fork●length. measurement The l measurement is the Truck●length●including●back●of●fork.

• Page 54
  Technical information u measurement The u measurement is the distance between fork● tip● and● the● wheel-fork● pivot● point. T measurement The measurement from●back●of●forks●to●the●wheel●fork●pivot●point is called the T measurement. The T measurement can be calculated with the formula: T = l -u As an example the u and T measurements are important for long side handling of pallets.
• Page 55
  Technical information Standard fork length tables LWE140/160 X down, Fl-u+119 X up, Fl-u+64 1000 1070 1120 1150 1200 1220 1019 1370 1085 1204 1149 1450 1165 1284 1229 1520 1235 1354 1299 LWE180/200/250 X down, Fl-u+116 X up, Fl-u+59 1000 1050 1070 1100…
• Page 56
  Technical information e, b and b measurements LWE140 LWE160 LWE180 LWE200 LWE250 measurement, height of fork in lowered position measurement, height of fork in raised position. e measurement, fork width measurement, width over forks The b measurement is referred to as the width●over●forks. This measurement must suit the pallets to be handled by the truck.

• Page 57: Aisle Width Requirement

  Technical information , turning radius The turning radius is the necessary Distance●to●turn●the●truck●around●a●virtual● point●referred●to●as●the●turning●centre with forks raised. The product informa- tion provides Wa measurements for all LWE truck versions. – Aisle width requirement The aisle width requirement can be described as the space required by the truck to pick a pallet from a pallet rack, reverse out in the aisle, turn and proceed down the aisle.

• Page 58: Aisle Width Requirements

  Technical information Aisle width requirements Truck Battery comp. Aisle width for pallets: LWE140 small 1420 1842 1000×1200 longside handling small 1420 1892 800×1200 shortside handling Truck Battery comp. Aisle width for pallets: LWE160 small 1420 1842 1000×1200 longside handling small 1420 1892 800×1200 shortside handling…

• Page 59
  Technical information Calculating A according to the standard, LWE range ● The values are from the Product information sheet for LWE200. Standard: A = 1447 + (1200 — 898) + 2×100 = 1949 Length of pallet must be substituted by total fork length Standard: A = 1447+ (1150 — 898) + 2×100 = 1899…

• Page 60: Pallets And Pallet Sizes

  Technical information Pallets and pallet sizes 1200 Euro pallet 382,5 382,5 ● Outer dimensions: 800 × 1200 mm ● Pallet height: 144 mm 227,5 227,5 ● Height, fork entries: 100 all four sides ● Corners: 45° ● Pallet weight: approximately 27 kg ●…

• Page 61: Choosing The Optimal Fork Specification

  Technical information Choosing the optimal fork specification When forks suited for a pallet or a specific roll container, these items should be considered: ● The b measurement must suit the pallet /roll container to enable positioning of the forks between the pallet legs or between the wheels of the roll container. Example: With Width over Forks 450 mm and Fork Width 180 mm, only 90 mm remains between the forks and the truck will not be able to handle Euro pallets or Chep pallets.

• Page 62: Battery Weights

  Technical information Battery weights LWE140 Batt. compartment Min. batt. weight kg Max. batt. weight kg Capacity Ah Volt V Size L*W*H mm Small 651 x 150 x 570 LWE160 Batt. compartment Min. batt. weight kg Max. batt. weight kg Capacity Ah Volt V Size L*W*H mm Small 651 x 150 x 570 Medium…

• Page 63: Battery And Charger

  Technical information Battery and charger Information on Hawker Evolution GEL batteries Hawker Evolution GEL batteries is the only type of valve-regulated batteries of- fered for the trucks in the LWE series. Please note the following if selecting a bat- tery of this type for the truck: ●…

• Page 64
  Technical information Product guide – BT Levio W-series…

• Page 65: Options

  Options Options To adapt the truck to customer preferences, a number of options are available. Battery change from the side Battery roller bed which enables lateral battery replacement (only for trucks with a large bat- tery compartment). Not available for LWE140, LWE160 and LWE180.

• Page 66: Battery Change Table

  Options Battery change table To facilitate battery change from the side, an exter- nal battery change table is also available. The height from the floor to the top of the rollers is adjustable. The battery change table measurments are 834 x 912 mm.

• Page 67: Built-In Charger

  Options Built-in charger When connected to 230 V, the charger has a capacity of 30 A.It is self-adjusting and can be used for voltages between 90 V and 255 V AC, 45 to 400 Hz. For voltages under 200 V, the output current will be reduced. Freely ventilated batteries up to 320 Ah and valve regulated batteries from 134 to 213 Ah can be charged.

• Page 68: Spacer For Long Side Pallet Handling

  Options Feature Any error codes generated by the battery charger are displayed on the display. Benefit This simplifies fault diagnosis if required. Feature When the built-in charger is used, it is not possible to charge the battery unless the battery cover is opened since the power cord needs to be pulled out from behind the cover.

• Page 69: Truck Log Systems

  Truck log systems Toyota I-site Toyota I-site is a truck log and fleet management system that provides possibili- ties to monitor truck usage and operator performance. Toyota I-site is offered a monthly fee basis where we provide a continual process of analysis and consul- tancy to customers and give them access to our knowledge and skills to help us build customer relations.

• Page 70
  Options If the shock sensor is included in the system, information about collisions and im- pacts can be viewed. By monitoring truck usage and operator performance, customers can improve op- erations and reduce cost. Access to different levels of information can be set for different users/functions in the company.

• Page 71: Integrated E-Bar With Optional Accessories

  Options Integrated E-bar with optional accessories All trucks in the LWE series, except for those with small battery compartment, can be fitted with an optional E-bar. This is BT’s standard solution for mounting a writing holder, plastic film holder, computer terminal, PC, scanner or other electronic equipment required onboard the truck.

• Page 72: Turtle Button

  Options Turtle button The turtle button allows temporary reduction of speed. The default setting for speed reduction is – 50 %, i.e. the travel speed will be reduced to 3 km/h. If necessary, this can be reprogrammed by a service technician. Feature When the turtle button is pressed once, the truck enters the turtle mode and travels at reduced speed.

• Page 73: Operator Platform

  Options Operator platform An operator platform is a useful option if the travel distances are a bit longer and the operator wants to have the comfort of a stand-on platform. The LWE series offers two different platform types, one with a rubber mat and automatic fold-up and a cold-store version with a checkered plate and also automatic fold-up.

• Page 74
  Options Feature The cold-store version of the platform uses a checkered plate. Benefit The checkered plate assures good friction even in cold stores and also in foodstuff applications where operators often wear wet or slippery shoes. Feature The platform is secured to a frame with rounded corners. Benefit The frame offers numerous benefits: ●…

• Page 75: Load Support

  Options Load support The optional load support is attached to the back of the forks and is available on all LWE trucks. Feature The load support has a height of 1500 mm (from the top of the forks). Benefit This added support protects the operator and goods.

• Page 76: Rubber Border

  Options Rubber border A rubber border is available for all BT Levio W-series models. The trucks can be ordered with a rubber border instead of the standard steel border to allow high gradient ramp handling ability. The rubber border is especially suited for applications with high thresholds, curbs and ramps with high gradients.

• Page 77: Appendix

  Appendix Appendix Environmental work within BT The BT trucks are produced at manufacturing sites where environmental issues are in focus. Waste management and reduction of hazardous chemicals used in production are natural parts of the everyday environmental work. We have been ISO 14001 certified since 1997, and in our continuous environmental work we put effort into reducing energy consumption on all levels, while we work with preven- tive actions to reduce pollution risks and the risk of biological danger.

• Page 78: Focus On Quality Within Bt

  Appendix Focus on quality within BT The Toyota Way is based on the Guiding Principles at Toyota. Its five core values express the beliefs and values used in the daily work: Challenge To maintain a long-term vision and meet all challenges with the courage and crea- tivity needed to realise that vision.

• Page 79
  Appendix Products and components are tested and evaluated throughout the development process, both in lab environments and field tests. 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 continuously monitored during manufacturing through welding audits on components and product audits on completed trucks.

• Page 80: Certificates

  Appendix Certificates Product guide – BT Levio W-series…

• Page 81
  Appendix Product guide – BT Levio W-series…