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Master Service Manual
Read and observe all warnings on this unit
before operating it.
DO NOT operate this equipment unless all
factory installed guards and shields are
properly secured in place.
WARNING
WARNING
Part no: 00700-CL3WS-RP Date: August 01, 2002
Front Cover
6BWC10/15/20 6BWS11/15/20 6BWR15
Electric Walkie High Lifter Trucks
Effective Serial Number 6BWC10-20001 - UP
30459
7-000
304597-0
00
304597-0
00
6BWC 6BWS
6BWR
Standard Codes
F-code Section C-code
Version no T-code
001
Toyota 1
2002-08-01
Master Service Manual
Standard Codes
B-Code = Business area
F-Code = Product family
T-Code = Product type
C-Code = Component function
Worksheet standard
W-Code = Working code
R-Code = Reason code
SO-Code = Assortment
F-Code List
PS Powered Pallet Stackers
T-Code List
No. Model
6BWC 6BWC10/15/20
6BWS 6BWS11/15/20
6BWR 6BWR15
C-Code List
No Function Group C-Code
0 Chassis 0000
1 Motors 1000
2 Drive Gear / Transmission 2000
3 Brake / Wheel System 3000
4 Steering System 4000
5 Electrical System 5000
6 Hydraulic / Pneumatic System 6000
7 Operating Function-lifting Mast / Cylinders 7000
001
Version no T-code
F-code Section C-code
Standard Codes
2 2002-08-01
Master Service Manual
8 Peripheral / Installation Equipment 8000
9 Optionals / Attachments 9000
10 Tools 10000
Table of Contents
Toyota 3
2002-08-01
Master Service Manual
Standard Codes ........................................................................................................ 1
Warning Symbols ..................................................................................................... 13
Warning Levels .................................................................................................... 13
Prohibitory Symbols ................................................................................................ 14
Ordinance Symbols .............................................................................................. 14
Safety ........................................................................................................................ 15
General Safety ..................................................................................................... 15
Battery Safety ........................................................................................................... 19
Static Safety ............................................................................................................. 24
Welding Safety ......................................................................................................... 25
Introduction, Service Manual .................................................................................. 27
Contents, Section M ................................................................................................ 29
Machine Information ............................................................................................ 29
General Product Information .................................................................................. 31
Presentation of Walkie Trucks. ............................................................................ 31
Truck Side Views ........................................................................................ 32
Intended Truck Application .......................................................................... 32
Prohibited Truck Application ....................................................................... 32
Truck Data ................................................................................................... 33
6BWC10 Dimensions .................................................................................. 34
6BWC15 Dimensions .................................................................................. 35
6BWC20 Dimensions .................................................................................. 36
6BWS11 Dimensions .................................................................................. 37
6BWS15 Dimensions .................................................................................. 38
6BWS20 Dimensions .................................................................................. 39
6BWR15 Dimensions .................................................................................. 40
Data Plate ................................................................................................... 41
Main Components ................................................................................................ 42
Inch (SAE) and Metric Fasteners ........................................................................... 45
Introduction .......................................................................................................... 45
Nomenclature, Threads ........................................................................................ 46
Strength Identification .......................................................................................... 47
Conversion of Metric and English Units ............................................................... 54
Technical Service Data ............................................................................................ 57
Ordering Spare Parts ............................................................................................... 61
Contents, Section P ................................................................................................. 63
Table of Contents
4 2002-08-01
Master Service Manual
Planned Maintenance .......................................................................................... 63
Introduction, Maintenance ...................................................................................... 65
Jacking Truck Off The Floor ................................................................................. 66
Elevate Rear of Truck ................................................................................. 66
Elevate Either Side of Truck ........................................................................ 66
Lubricants ............................................................................................................ 67
Standard ...................................................................................................... 67
Corrosion ..................................................................................................... 67
Cold Storage ............................................................................................... 68
Service Schedule ..................................................................................................... 71
Planned Maintenance Schedule .......................................................................... 71
Planned Maintenance Procedures ....................................................................... 76
Services Performed Daily or Every 8 Operating Hours ............................... 76
Services Performed Monthly or Every 120 Operating Hours. ..................... 77
Services Performed Every 480 or 960 Operating Hours ............................. 80
Services Performed Annually or Every 1400 Operating Hours ................... 81
Lubrication Chart ..................................................................................................... 83
Oil and Grease Specifications ................................................................................ 84
Approved Oils and Grease ................................................................................... 84
6BWC Grease & Mast Adjustment Points Location ............................................. 85
6BWS Grease & Mast Adjustment Points Location ............................................. 86
6BWR Grease & Mast Adjustment Points Location ............................................. 87
Contents, Section S ................................................................................................. 89
Service Instructions .............................................................................................. 89
Frame/Chassis ......................................................................................................... 91
General ................................................................................................................ 93
Main Components ................................................................................................ 93
Inspection Covers .................................................................................................... 95
Battery Roller (Optional) ........................................................................................ 103
Battery Cover, Optional (6BWS11 “EE” Trucks Only) ......................................... 105
Inspection ................................................................................................... 105
Removal ..................................................................................................... 105
Installation .................................................................................................. 106
Battery Rollers .................................................................................................... 106
Inspection ................................................................................................... 106
Replacement .............................................................................................. 106
Driver Controls, One Spool .................................................................................... 107
Removal .............................................................................................................. 109
Installation ........................................................................................................... 110
Table of Contents
Toyota 5
2002-08-01
Master Service Manual
Driver Controls, Two Spool .................................................................................... 111
Removal .............................................................................................................. 114
Installation ........................................................................................................... 115
Decals ...................................................................................................................... 117
Decal with Protective Sheet ................................................................................ 117
Decal without Protective Sheet ........................................................................... 117
Motor Maintenance
Schedule/Troubleshooting ..................................................................................... 119
General Information ............................................................................................ 119
Operating Conditions .......................................................................................... 119
Troubleshooting .................................................................................................. 120
Motor Repair ............................................................................................................ 127
Pump Motor ....................................................................................................... 127
Pump Motor Removal ................................................................................ 128
Pump Motor Installation ............................................................................. 128
Drive Motor ......................................................................................................... 129
Brush Replacement .................................................................................... 133
Drive Motor Removal ................................................................................. 133
Drive Motor Installation .............................................................................. 134
Component Repair .............................................................................................. 136
Disassembly .............................................................................................. 136
Inspection ............................................................................................................ 138
Drive End head .......................................................................................... 138
Commutator End Head .............................................................................. 138
Bearings ..................................................................................................... 138
Brush and Commutator .............................................................................. 139
Armature .................................................................................................... 141
Frame and Field Assembly ........................................................................ 142
Assembly/Testing ....................................................................................... 143
Transmission ........................................................................................................... 145
System Description ............................................................................................. 145
Troubleshooting .................................................................................................. 145
Kick Panel .................................................................................................. 146
Transmission Repair ........................................................................................... 147
Removal ..................................................................................................... 148
Installation .................................................................................................. 149
Transmission Assembly ...................................................................................... 151
Disassembly ............................................................................................... 152
Assembly .................................................................................................... 152
Axle Seal ............................................................................................................. 154
Removal ..................................................................................................... 154
Installation .................................................................................................. 154
Parking Brake System ............................................................................................ 157
Brake Theory of Operation .................................................................................. 159
Table of Contents
6 2002-08-01
Master Service Manual
Brake Adjustment ................................................................................................ 160
Brake Shoe Removal / Installation ...................................................................... 161
Drive Wheel ............................................................................................................. 163
Removal .............................................................................................................. 163
Installation ........................................................................................................... 164
Tire Pressing Procedure ..................................................................................... 165
Support/Swivel Wheel ............................................................................................ 167
Maintenance and Adjustments ............................................................................ 170
Caster Adjustment ...................................................................................... 171
Troubleshooting .................................................................................................. 172
Stabilizing Caster ....................................................................................... 172
Load Wheels ............................................................................................................ 173
Removal and Installation ..................................................................................... 176
Caster Assembly ..................................................................................................... 177
Disassembly ........................................................................................................ 178
Inspection ............................................................................................................ 179
Assembly ............................................................................................................ 180
Installation ........................................................................................................... 181
Steering Arm/Wheel, Tiller Arm ............................................................................. 183
Removal .............................................................................................................. 184
Inspection ............................................................................................................ 185
Installation ........................................................................................................... 186
Steering Arm/Wheel, Head ..................................................................................... 187
Control Handle Head .......................................................................................... 188
Removal ..................................................................................................... 188
Installation .................................................................................................. 188
Direction Control Switches .................................................................................. 189
Raise, Lower, and Horn Switches ....................................................................... 191
Potentiometer ...................................................................................................... 194
Removal ..................................................................................................... 194
Installation .................................................................................................. 195
Reverser Assembly Replacement ....................................................................... 199
Electrical Functions ................................................................................................ 201
General ............................................................................................................... 201
Adjustable Settings .................................................................................... 201
References ................................................................................................. 201
Key Switch S17 in ON Position .................................................................. 202
Operating Arm in Drive Position, S10, Brake Switch Closed ..................... 202
Travel Request, Forks First ........................................................................ 202
Travel Request, Forks Trailing ................................................................... 202
Reversing/Motor Brake Forks First to Forks Trailing Direction ................... 203
Reversing/Motor Brake Forks Trailing to Forks First Direction ................... 203
Table of Contents
Toyota 7
2002-08-01
Master Service Manual
Reverser switch .......................................................................................... 203
Lifting Forks ................................................................................................ 203
Lowering Forks ........................................................................................... 204
Horn ........................................................................................................... 204
Options ................................................................................................................ 204
Lifting Forks (Manual Valve) ...................................................................... 204
Tilting Forks ................................................................................................ 204
Side Shifting Forks ..................................................................................... 204
Extend/Retract Forks ................................................................................. 205
Electrical Symbols .................................................................................................. 207
Electrical Schematics ............................................................................................. 213
Battery ...................................................................................................................... 219
Removal .............................................................................................................. 219
Installation ........................................................................................................... 220
Battery Maintenance ........................................................................................... 221
Battery Inspection and Care ....................................................................... 221
Battery Exterior Cleaning ........................................................................... 222
Charging ..................................................................................................... 222
Storage ............................................................................................................... 223
Battery History Record ........................................................................................ 223
Battery Connector ................................................................................................... 225
Location .............................................................................................................. 225
Inspection ............................................................................................................ 226
Installation ........................................................................................................... 226
200 Amp System Line Contactor .......................................................................... 229
Replacement ....................................................................................................... 229
Removal ..................................................................................................... 229
Installation .................................................................................................. 229
300 Amp System Line Contactor (6BWC15/20 only) .......................................... 231
Maintenance ....................................................................................................... 231
Removal/Replacement of Contact Tips ...................................................... 232
200/300 Amp System “EE” Line Contactor ......................................................... 233
Maintenance ....................................................................................................... 233
Removal/Replacement of Contact Tips ...................................................... 234
Battery Controller/Hourmeter/Lift Interrupt .......................................................... 237
General Information ............................................................................................ 237
Electrical ............................................................................................................. 238
Voltage ....................................................................................................... 238
Battery Controller (BC) ........................................................................................ 239
General Information ................................................................................... 239
Reset .......................................................................................................... 241
Table of Contents
8 2002-08-01
Master Service Manual
Key Switch ................................................................................................. 241
Hourmeter .................................................................................................. 242
Troubleshooting .................................................................................................. 242
Battery Discharge Indicator (BDI) .............................................................. 242
Hourmeter .................................................................................................. 245
Start/Stop Switches ................................................................................................ 247
General ............................................................................................................... 247
Test/Inspection ........................................................................................... 247
Master Control On/Off Switch (S21) .................................................................... 249
Inspection ................................................................................................... 249
Removal ..................................................................................................... 249
Installation .................................................................................................. 249
Light Assemblies .................................................................................................... 251
Warning Lights (Option) ...................................................................................... 251
Removal ..................................................................................................... 253
Installation .................................................................................................. 253
Travel/Back-up Alarm (Option) ............................................................................ 254
Removal ..................................................................................................... 254
Installation .................................................................................................. 254
Transistor Controller .............................................................................................. 255
Basics Of Circuit Operation ................................................................................. 255
Control Features ........................................................................................ 257
Maintenance ....................................................................................................... 258
Safety ......................................................................................................... 258
Cleaning ..................................................................................................... 258
Motor Circuit ........................................................................................................ 259
Control Circuit ..................................................................................................... 260
Troubleshooting Guidelines ................................................................................ 261
General ...................................................................................................... 263
Shorts to Frame Test .......................................................................................... 264
Definitions ........................................................................................................... 268
Diagnostics and Troubleshooting ........................................................................ 269
Handset Diagnostics .................................................................................. 269
Troubleshooting ......................................................................................... 269
Troubleshooting Chart ................................................................................ 271
Technical Specification .............................................................................. 276
Troubleshooting Chart Using Handset ....................................................... 277
Transistor Controller Troubleshooting ................................................................. 279
Troubleshooting Chart Index ............................................................................... 279
Troubleshooting Charts ....................................................................................... 280
Hydraulic System .................................................................................................... 299
General ............................................................................................................... 299
Description of Function ....................................................................................... 299
Main Components ............................................................................................... 300
Table of Contents
Toyota 9
2002-08-01
Master Service Manual
Lift (Solenoid valve) .................................................................................... 300
Lift (Mechanical Valve) ............................................................................... 300
Lower (Solenoid Valve) .............................................................................. 300
Lower (Mechanical Valve) .......................................................................... 300
Relief Pressure ........................................................................................... 300
Compensating Cylinder .............................................................................. 301
Reach (Solenoid valve) .............................................................................. 301
Tilt (Solenoid valve) .................................................................................... 301
Sideshift (Solenoid valve) ........................................................................... 301
Maintenance ....................................................................................................... 302
Adjustments ........................................................................................................ 303
Troubleshooting .................................................................................................. 304
Primary Malfunctions .................................................................................. 305
Definitions ........................................................................................................... 306
Removal .............................................................................................................. 307
Installation ........................................................................................................... 309
Hydraulic Schematics ............................................................................................. 311
Hydraulic Fluid ........................................................................................................ 315
Hydraulic Fluid Selection ..................................................................................... 315
Changing Hydraulic System Fluid ....................................................................... 315
System Draining .................................................................................................. 316
Refilling System .................................................................................................. 317
Bleeding Hydraulic System ................................................................................. 318
Hydraulic Tank ........................................................................................................ 319
Removal .............................................................................................................. 320
Installation ........................................................................................................... 320
Hydraulic Pump Assembly ..................................................................................... 321
Disassembly ........................................................................................................ 323
Inspection ............................................................................................................ 324
Assembly ............................................................................................................ 325
One Spool Control Valve ........................................................................................ 327
Operators Controls Removal ............................................................................... 328
Control Valve Disassembly and Inspection ......................................................... 328
Operators Controls Installation ............................................................................ 329
Two Spool Control Valve ........................................................................................ 330
Operators Controls Removal ............................................................................... 331
Control Valve Disassembly and Inspection ......................................................... 331
Operators Controls Installation ............................................................................ 332
Lift Cylinder, Two Stage Mast ............................................................................. 337
Removal ..................................................................................................... 337
Disassembly ............................................................................................... 338
Assembly .................................................................................................... 338
Installation .................................................................................................. 338
Table of Contents
10 2002-08-01
Master Service Manual
Two Stage Full Freelift Mast Cylinder Repair ...................................................... 339
Removal ..................................................................................................... 339
Disassembly ............................................................................................... 340
Assembly .................................................................................................... 340
Installation .................................................................................................. 340
Two Stage Full Freelift Mast Staging Cylinder Repair ........................................ 341
Removal ..................................................................................................... 341
Disassembly ............................................................................................... 342
Assembly .................................................................................................... 342
Installation .................................................................................................. 342
Lift Cylinder, Three Stage Mast ............................................................................ 343
Repair ................................................................................................................. 346
Removal ..................................................................................................... 346
Disassembly ............................................................................................... 347
Assembly .................................................................................................... 347
Installation .................................................................................................. 347
Reach Cylinder, 6BWR15 ....................................................................................... 349
Removal .............................................................................................................. 351
Disassembly ........................................................................................................ 352
Inspection ............................................................................................................ 353
Assembly ............................................................................................................ 354
Installation ........................................................................................................... 355
Tilt Cylinder ............................................................................................................. 357
Removal .............................................................................................................. 359
Disassembly ........................................................................................................ 360
Inspection ............................................................................................................ 361
Assembly ............................................................................................................ 362
Installation ........................................................................................................... 363
Removal .............................................................................................................. 365
Disassembly ........................................................................................................ 366
Inspection ............................................................................................................ 367
Assembly ............................................................................................................ 368
Installation ........................................................................................................... 369
Shimming Carriage with Mast on Truck. ............................................................. 377
Repair ................................................................................................................. 379
Removal ..................................................................................................... 379
Disassembly ............................................................................................... 380
Assembly .................................................................................................... 381
Installation .................................................................................................. 383
Lift Chain ............................................................................................................. 384
Lift Chain Adjustment: ................................................................................ 384
Lift Chain Maintenance .............................................................................. 384
Lift Chain Inspection ................................................................................... 384
Lift Chain Replacement .............................................................................. 391
Mast, Three Stage ................................................................................................... 393
Table of Contents
Toyota 11
2002-08-01
Master Service Manual
Shimming Carriage with Mast on Truck. ............................................................. 399
Repair ................................................................................................................. 401
Removal ..................................................................................................... 401
Disassembly ............................................................................................... 402
Assembly .................................................................................................... 403
Installation .................................................................................................. 405
Lift Chain ............................................................................................................. 406
Sideshifter ............................................................................................................... 407
Mounting Instructions .......................................................................................... 409
Installation .................................................................................................. 409
Operation ............................................................................................................ 410
Maintenance ....................................................................................................... 410
Carriage Removal ...................................................................................... 411
Upper Pad Replacement ............................................................................ 411
Lower Pad Replacement ............................................................................ 412
Cylinder ...................................................................................................... 413
Troubleshooting .................................................................................................. 414
No Sideshifting ........................................................................................... 414
Very Slow Sideshifting ............................................................................... 414
Irregular Sideshifting .................................................................................. 415
Single Reach, 6BWR ............................................................................................... 417
Maintenance ....................................................................................................... 419
Inspection ................................................................................................... 419
Adjustment ................................................................................................. 420
Repair ................................................................................................................. 424
Disassembly ............................................................................................... 424
Assembly .................................................................................................... 426
Carriage Bumpers ............................................................................................... 428
Reach Adjustment ...................................................................................... 428
Fork Carriage Pivot Pins ..................................................................................... 430
Carriage Roller Bearings ..................................................................................... 430
Removal ..................................................................................................... 430
Installation .................................................................................................. 430
Removal .............................................................................................................. 432
Inspection ............................................................................................................ 432
Installation ........................................................................................................... 433
Load Backrest ......................................................................................................... 435
Removal .............................................................................................................. 436
Installation ........................................................................................................... 436
Handset Operation .................................................................................................. 437
Operating Modes ................................................................................................ 440
Revert to Previous Settings ................................................................................. 443
Handset Self Test ............................................................................................... 443
Electrical Controllers (Handset) ............................................................................ 445
Table of Contents
12 2002-08-01
Master Service Manual
Display Screen .................................................................................................... 446
Menu Navigation Key ................................................................................. 446
Data Inc/Dec Key ....................................................................................... 446
Bookmark Keys .......................................................................................... 446
Operation ............................................................................................................ 447
Menu Structure ........................................................................................... 447
Main Menu ................................................................................................. 448
Interface Protocols and Backward Compatibility ........................................ 449
Parameter Changing .................................................................................. 450
Real-Time Monitoring ................................................................................. 450
Reading Faults and Diagnostic History File ............................................... 451
Cloning and Restoring the Previous Programming .................................... 451
Information Displays ................................................................................... 452
Programmer SetUp .................................................................................... 452
Warning Symbols
F-code Section C-code
Version no T-code
001
Toyota 13
2002-08-01
Master Service Manual
Warning Symbols
Always follow the warnings given in this Instruction Manual
and on the truck to avoid accidents and incidents from
occurring.
1. Warning Levels
Warning levels
Warning text is given in four levels and provide information on
the risks, describe the consequences, and instruct how to
avoid accidents.
DANGER
Warns that an accident will occur if the instructions are not
followed.
The consequences are serious personal injury or possibly
death, and/or extremely large material damage.
WARNING
Warns that an accident can occur if the instructions are not
followed.
The consequences are serious personal injury or possibly
death, and/or large material damage.
CAUTION
Warns that an accident can occur if the instructions are not
followed.
The consequences are personal injury and/or material
damage.
NOTE!
Marks the risk of and accident or breakdown if the
instructions are not followed.
001
Version no T-code
F-code Section C-code
Prohibitory Symbols
14 2002-08-01
Master Service Manual
Prohibitory Symbols
NO SMOKING
If smoking occurs in situations where a restriction against
smoking is stated, a serious accident can occur.
OPEN FLAMES PROHIBITED
If open flames are used in situations where open flames are
prohibited, a serious accident can occur.
GENERAL PROHIBITION
If the prohibition is ignored, a serious accident can occur.
1. Ordinance Symbols
SAFETY SHOES
When the directive for safety shoes is given, safety shoes
shall always be worn to reduce personal injury.
PROTECTIVE GLASSES
When the directive for protective glasses is given,
protective glasses shall always be worn to reduce personal
injury.
Safety
F-code Section C-code
Version no T-code
001
Toyota 15
2002-08-01
Master Service Manual
Safety
1. General Safety
Do NOT operate or work on truck unless trained, qualified,
and authorized to do so and have read the Operator’s
Manual.
Know the truck controls and what they do.
Do NOT operate truck if it needs repair or if it is in any way
unsafe.
001
Version no T-code
F-code Section C-code
Safety
16 2002-08-01
Master Service Manual
Operate truck only from the operator’s position.
Before working on truck always turn key switch to OFF and
disconnect truck’s battery connector (unless this manual
states otherwise).
Do NOT wear watches, rings, or jewelry when working on
truck.
Safety
F-code Section C-code
Version no T-code
001
Toyota 17
2002-08-01
Master Service Manual
Follow the scheduled lubrication, maintenance, and
inspection steps.
Follow exactly the safety and repair instructions in this
manual. Do NOT take “shortcuts”.
Do NOT Use an open flame near the truck.
Do NOT use gasoline or other flammable liquids for cleaning
parts.
001
Version no T-code
F-code Section C-code
Safety
18 2002-08-01
Master Service Manual
Clean up any hydraulic fluid, oil, or grease that has leaked or
spilled on the floor.
Always operate and park truck indoors.
Do NOT wash truck with a hose.
Do NOT add to or modify truck without written approval from
Toyota
Battery Safety
F-code Section C-code
Version no T-code
001
Toyota 19
2002-08-01
Master Service Manual
Battery Safety
Read, understand and follow procedures, recommendations
and specifications in the battery and battery charger
manufacturer’s manuals.
As a battery is being charged, an explosive
gas mixture forms within and around each
cell. If the area is not properly ventilated,
this explosive gas can remain in or around
the battery for several hours after charging.
Be sure there are no open flames or sparks
in the charging area. An open flame or
spark can ignite this gas, resulting in
serious damage or injury.
Battery electrolyte is a solution of sulfuric
acid and water. Battery acid causes burns.
Should any electrolyte come in contact with
clothing or skin, flush the area immediately
with cold water. Should the solution get on
the face or in the eyes, flush the area with
cold water and get medical help
immediately.
WARNING
WARNING
Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
001
Version no T-code
F-code Section C-code
Battery Safety
20 2002-08-01
Master Service Manual
Wear personal protective equipment to protect eyes, face,
and skin when checking, handling, or filling batteries. This
equipment includes goggles or face shield, rubber gloves
(with or without arm shields) and a rubber apron.
Make sure a shower and eyewash station are nearby in case
there is an accident.
A battery gives off explosive gases. Never smoke, use an
open flame, or use anything that gives off sparks near a
battery.
Battery Safety
F-code Section C-code
Version no T-code
001
Toyota 21
2002-08-01
Master Service Manual
Keep the charger area well-ventilated to avoid hydrogen gas
concentration.
Turn the key switch off before disconnecting the battery from
the truck at the battery connector. Do NOT break live circuits
at the battery terminals. A spark often occurs at the point
where a live circuit is broken.
Do NOT lay tools or metal objects on top of battery. A short
circuit or explosion could result.
001
Version no T-code
F-code Section C-code
Battery Safety
22 2002-08-01
Master Service Manual
Keep batteries clean. Corrosion causes shorts to the frame
and possibly sparks.
Keep plugs, terminals, cables, and receptacles in good
condition to avoid shorts and sparks.
Keep filler plugs firmly in place at all times except when the
electrolyte level is checked, when water is added to the cells
or when the specific gravity is checked.
Make sure vent holes in filler plugs are open to allow gas to
escape from the cells.
Vent Plug

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Toyota 6 bwr15 electric walkie high lifter truck service repair manual

  • 1. Master Service Manual Read and observe all warnings on this unit before operating it. DO NOT operate this equipment unless all factory installed guards and shields are properly secured in place. WARNING WARNING Part no: 00700-CL3WS-RP Date: August 01, 2002 Front Cover 6BWC10/15/20 6BWS11/15/20 6BWR15 Electric Walkie High Lifter Trucks Effective Serial Number 6BWC10-20001 - UP 30459 7-000 304597-0 00 304597-0 00 6BWC 6BWS 6BWR
  • 2. Standard Codes F-code Section C-code Version no T-code 001 Toyota 1 2002-08-01 Master Service Manual Standard Codes B-Code = Business area F-Code = Product family T-Code = Product type C-Code = Component function Worksheet standard W-Code = Working code R-Code = Reason code SO-Code = Assortment F-Code List PS Powered Pallet Stackers T-Code List No. Model 6BWC 6BWC10/15/20 6BWS 6BWS11/15/20 6BWR 6BWR15 C-Code List No Function Group C-Code 0 Chassis 0000 1 Motors 1000 2 Drive Gear / Transmission 2000 3 Brake / Wheel System 3000 4 Steering System 4000 5 Electrical System 5000 6 Hydraulic / Pneumatic System 6000 7 Operating Function-lifting Mast / Cylinders 7000
  • 3. 001 Version no T-code F-code Section C-code Standard Codes 2 2002-08-01 Master Service Manual 8 Peripheral / Installation Equipment 8000 9 Optionals / Attachments 9000 10 Tools 10000
  • 4. Table of Contents Toyota 3 2002-08-01 Master Service Manual Standard Codes ........................................................................................................ 1 Warning Symbols ..................................................................................................... 13 Warning Levels .................................................................................................... 13 Prohibitory Symbols ................................................................................................ 14 Ordinance Symbols .............................................................................................. 14 Safety ........................................................................................................................ 15 General Safety ..................................................................................................... 15 Battery Safety ........................................................................................................... 19 Static Safety ............................................................................................................. 24 Welding Safety ......................................................................................................... 25 Introduction, Service Manual .................................................................................. 27 Contents, Section M ................................................................................................ 29 Machine Information ............................................................................................ 29 General Product Information .................................................................................. 31 Presentation of Walkie Trucks. ............................................................................ 31 Truck Side Views ........................................................................................ 32 Intended Truck Application .......................................................................... 32 Prohibited Truck Application ....................................................................... 32 Truck Data ................................................................................................... 33 6BWC10 Dimensions .................................................................................. 34 6BWC15 Dimensions .................................................................................. 35 6BWC20 Dimensions .................................................................................. 36 6BWS11 Dimensions .................................................................................. 37 6BWS15 Dimensions .................................................................................. 38 6BWS20 Dimensions .................................................................................. 39 6BWR15 Dimensions .................................................................................. 40 Data Plate ................................................................................................... 41 Main Components ................................................................................................ 42 Inch (SAE) and Metric Fasteners ........................................................................... 45 Introduction .......................................................................................................... 45 Nomenclature, Threads ........................................................................................ 46 Strength Identification .......................................................................................... 47 Conversion of Metric and English Units ............................................................... 54 Technical Service Data ............................................................................................ 57 Ordering Spare Parts ............................................................................................... 61 Contents, Section P ................................................................................................. 63
  • 5. Table of Contents 4 2002-08-01 Master Service Manual Planned Maintenance .......................................................................................... 63 Introduction, Maintenance ...................................................................................... 65 Jacking Truck Off The Floor ................................................................................. 66 Elevate Rear of Truck ................................................................................. 66 Elevate Either Side of Truck ........................................................................ 66 Lubricants ............................................................................................................ 67 Standard ...................................................................................................... 67 Corrosion ..................................................................................................... 67 Cold Storage ............................................................................................... 68 Service Schedule ..................................................................................................... 71 Planned Maintenance Schedule .......................................................................... 71 Planned Maintenance Procedures ....................................................................... 76 Services Performed Daily or Every 8 Operating Hours ............................... 76 Services Performed Monthly or Every 120 Operating Hours. ..................... 77 Services Performed Every 480 or 960 Operating Hours ............................. 80 Services Performed Annually or Every 1400 Operating Hours ................... 81 Lubrication Chart ..................................................................................................... 83 Oil and Grease Specifications ................................................................................ 84 Approved Oils and Grease ................................................................................... 84 6BWC Grease & Mast Adjustment Points Location ............................................. 85 6BWS Grease & Mast Adjustment Points Location ............................................. 86 6BWR Grease & Mast Adjustment Points Location ............................................. 87 Contents, Section S ................................................................................................. 89 Service Instructions .............................................................................................. 89 Frame/Chassis ......................................................................................................... 91 General ................................................................................................................ 93 Main Components ................................................................................................ 93 Inspection Covers .................................................................................................... 95 Battery Roller (Optional) ........................................................................................ 103 Battery Cover, Optional (6BWS11 “EE” Trucks Only) ......................................... 105 Inspection ................................................................................................... 105 Removal ..................................................................................................... 105 Installation .................................................................................................. 106 Battery Rollers .................................................................................................... 106 Inspection ................................................................................................... 106 Replacement .............................................................................................. 106 Driver Controls, One Spool .................................................................................... 107 Removal .............................................................................................................. 109 Installation ........................................................................................................... 110
  • 6. Table of Contents Toyota 5 2002-08-01 Master Service Manual Driver Controls, Two Spool .................................................................................... 111 Removal .............................................................................................................. 114 Installation ........................................................................................................... 115 Decals ...................................................................................................................... 117 Decal with Protective Sheet ................................................................................ 117 Decal without Protective Sheet ........................................................................... 117 Motor Maintenance Schedule/Troubleshooting ..................................................................................... 119 General Information ............................................................................................ 119 Operating Conditions .......................................................................................... 119 Troubleshooting .................................................................................................. 120 Motor Repair ............................................................................................................ 127 Pump Motor ....................................................................................................... 127 Pump Motor Removal ................................................................................ 128 Pump Motor Installation ............................................................................. 128 Drive Motor ......................................................................................................... 129 Brush Replacement .................................................................................... 133 Drive Motor Removal ................................................................................. 133 Drive Motor Installation .............................................................................. 134 Component Repair .............................................................................................. 136 Disassembly .............................................................................................. 136 Inspection ............................................................................................................ 138 Drive End head .......................................................................................... 138 Commutator End Head .............................................................................. 138 Bearings ..................................................................................................... 138 Brush and Commutator .............................................................................. 139 Armature .................................................................................................... 141 Frame and Field Assembly ........................................................................ 142 Assembly/Testing ....................................................................................... 143 Transmission ........................................................................................................... 145 System Description ............................................................................................. 145 Troubleshooting .................................................................................................. 145 Kick Panel .................................................................................................. 146 Transmission Repair ........................................................................................... 147 Removal ..................................................................................................... 148 Installation .................................................................................................. 149 Transmission Assembly ...................................................................................... 151 Disassembly ............................................................................................... 152 Assembly .................................................................................................... 152 Axle Seal ............................................................................................................. 154 Removal ..................................................................................................... 154 Installation .................................................................................................. 154 Parking Brake System ............................................................................................ 157 Brake Theory of Operation .................................................................................. 159
  • 7. Table of Contents 6 2002-08-01 Master Service Manual Brake Adjustment ................................................................................................ 160 Brake Shoe Removal / Installation ...................................................................... 161 Drive Wheel ............................................................................................................. 163 Removal .............................................................................................................. 163 Installation ........................................................................................................... 164 Tire Pressing Procedure ..................................................................................... 165 Support/Swivel Wheel ............................................................................................ 167 Maintenance and Adjustments ............................................................................ 170 Caster Adjustment ...................................................................................... 171 Troubleshooting .................................................................................................. 172 Stabilizing Caster ....................................................................................... 172 Load Wheels ............................................................................................................ 173 Removal and Installation ..................................................................................... 176 Caster Assembly ..................................................................................................... 177 Disassembly ........................................................................................................ 178 Inspection ............................................................................................................ 179 Assembly ............................................................................................................ 180 Installation ........................................................................................................... 181 Steering Arm/Wheel, Tiller Arm ............................................................................. 183 Removal .............................................................................................................. 184 Inspection ............................................................................................................ 185 Installation ........................................................................................................... 186 Steering Arm/Wheel, Head ..................................................................................... 187 Control Handle Head .......................................................................................... 188 Removal ..................................................................................................... 188 Installation .................................................................................................. 188 Direction Control Switches .................................................................................. 189 Raise, Lower, and Horn Switches ....................................................................... 191 Potentiometer ...................................................................................................... 194 Removal ..................................................................................................... 194 Installation .................................................................................................. 195 Reverser Assembly Replacement ....................................................................... 199 Electrical Functions ................................................................................................ 201 General ............................................................................................................... 201 Adjustable Settings .................................................................................... 201 References ................................................................................................. 201 Key Switch S17 in ON Position .................................................................. 202 Operating Arm in Drive Position, S10, Brake Switch Closed ..................... 202 Travel Request, Forks First ........................................................................ 202 Travel Request, Forks Trailing ................................................................... 202 Reversing/Motor Brake Forks First to Forks Trailing Direction ................... 203 Reversing/Motor Brake Forks Trailing to Forks First Direction ................... 203
  • 8. Table of Contents Toyota 7 2002-08-01 Master Service Manual Reverser switch .......................................................................................... 203 Lifting Forks ................................................................................................ 203 Lowering Forks ........................................................................................... 204 Horn ........................................................................................................... 204 Options ................................................................................................................ 204 Lifting Forks (Manual Valve) ...................................................................... 204 Tilting Forks ................................................................................................ 204 Side Shifting Forks ..................................................................................... 204 Extend/Retract Forks ................................................................................. 205 Electrical Symbols .................................................................................................. 207 Electrical Schematics ............................................................................................. 213 Battery ...................................................................................................................... 219 Removal .............................................................................................................. 219 Installation ........................................................................................................... 220 Battery Maintenance ........................................................................................... 221 Battery Inspection and Care ....................................................................... 221 Battery Exterior Cleaning ........................................................................... 222 Charging ..................................................................................................... 222 Storage ............................................................................................................... 223 Battery History Record ........................................................................................ 223 Battery Connector ................................................................................................... 225 Location .............................................................................................................. 225 Inspection ............................................................................................................ 226 Installation ........................................................................................................... 226 200 Amp System Line Contactor .......................................................................... 229 Replacement ....................................................................................................... 229 Removal ..................................................................................................... 229 Installation .................................................................................................. 229 300 Amp System Line Contactor (6BWC15/20 only) .......................................... 231 Maintenance ....................................................................................................... 231 Removal/Replacement of Contact Tips ...................................................... 232 200/300 Amp System “EE” Line Contactor ......................................................... 233 Maintenance ....................................................................................................... 233 Removal/Replacement of Contact Tips ...................................................... 234 Battery Controller/Hourmeter/Lift Interrupt .......................................................... 237 General Information ............................................................................................ 237 Electrical ............................................................................................................. 238 Voltage ....................................................................................................... 238 Battery Controller (BC) ........................................................................................ 239 General Information ................................................................................... 239 Reset .......................................................................................................... 241
  • 9. Table of Contents 8 2002-08-01 Master Service Manual Key Switch ................................................................................................. 241 Hourmeter .................................................................................................. 242 Troubleshooting .................................................................................................. 242 Battery Discharge Indicator (BDI) .............................................................. 242 Hourmeter .................................................................................................. 245 Start/Stop Switches ................................................................................................ 247 General ............................................................................................................... 247 Test/Inspection ........................................................................................... 247 Master Control On/Off Switch (S21) .................................................................... 249 Inspection ................................................................................................... 249 Removal ..................................................................................................... 249 Installation .................................................................................................. 249 Light Assemblies .................................................................................................... 251 Warning Lights (Option) ...................................................................................... 251 Removal ..................................................................................................... 253 Installation .................................................................................................. 253 Travel/Back-up Alarm (Option) ............................................................................ 254 Removal ..................................................................................................... 254 Installation .................................................................................................. 254 Transistor Controller .............................................................................................. 255 Basics Of Circuit Operation ................................................................................. 255 Control Features ........................................................................................ 257 Maintenance ....................................................................................................... 258 Safety ......................................................................................................... 258 Cleaning ..................................................................................................... 258 Motor Circuit ........................................................................................................ 259 Control Circuit ..................................................................................................... 260 Troubleshooting Guidelines ................................................................................ 261 General ...................................................................................................... 263 Shorts to Frame Test .......................................................................................... 264 Definitions ........................................................................................................... 268 Diagnostics and Troubleshooting ........................................................................ 269 Handset Diagnostics .................................................................................. 269 Troubleshooting ......................................................................................... 269 Troubleshooting Chart ................................................................................ 271 Technical Specification .............................................................................. 276 Troubleshooting Chart Using Handset ....................................................... 277 Transistor Controller Troubleshooting ................................................................. 279 Troubleshooting Chart Index ............................................................................... 279 Troubleshooting Charts ....................................................................................... 280 Hydraulic System .................................................................................................... 299 General ............................................................................................................... 299 Description of Function ....................................................................................... 299 Main Components ............................................................................................... 300
  • 10. Table of Contents Toyota 9 2002-08-01 Master Service Manual Lift (Solenoid valve) .................................................................................... 300 Lift (Mechanical Valve) ............................................................................... 300 Lower (Solenoid Valve) .............................................................................. 300 Lower (Mechanical Valve) .......................................................................... 300 Relief Pressure ........................................................................................... 300 Compensating Cylinder .............................................................................. 301 Reach (Solenoid valve) .............................................................................. 301 Tilt (Solenoid valve) .................................................................................... 301 Sideshift (Solenoid valve) ........................................................................... 301 Maintenance ....................................................................................................... 302 Adjustments ........................................................................................................ 303 Troubleshooting .................................................................................................. 304 Primary Malfunctions .................................................................................. 305 Definitions ........................................................................................................... 306 Removal .............................................................................................................. 307 Installation ........................................................................................................... 309 Hydraulic Schematics ............................................................................................. 311 Hydraulic Fluid ........................................................................................................ 315 Hydraulic Fluid Selection ..................................................................................... 315 Changing Hydraulic System Fluid ....................................................................... 315 System Draining .................................................................................................. 316 Refilling System .................................................................................................. 317 Bleeding Hydraulic System ................................................................................. 318 Hydraulic Tank ........................................................................................................ 319 Removal .............................................................................................................. 320 Installation ........................................................................................................... 320 Hydraulic Pump Assembly ..................................................................................... 321 Disassembly ........................................................................................................ 323 Inspection ............................................................................................................ 324 Assembly ............................................................................................................ 325 One Spool Control Valve ........................................................................................ 327 Operators Controls Removal ............................................................................... 328 Control Valve Disassembly and Inspection ......................................................... 328 Operators Controls Installation ............................................................................ 329 Two Spool Control Valve ........................................................................................ 330 Operators Controls Removal ............................................................................... 331 Control Valve Disassembly and Inspection ......................................................... 331 Operators Controls Installation ............................................................................ 332 Lift Cylinder, Two Stage Mast ............................................................................. 337 Removal ..................................................................................................... 337 Disassembly ............................................................................................... 338 Assembly .................................................................................................... 338 Installation .................................................................................................. 338
  • 11. Table of Contents 10 2002-08-01 Master Service Manual Two Stage Full Freelift Mast Cylinder Repair ...................................................... 339 Removal ..................................................................................................... 339 Disassembly ............................................................................................... 340 Assembly .................................................................................................... 340 Installation .................................................................................................. 340 Two Stage Full Freelift Mast Staging Cylinder Repair ........................................ 341 Removal ..................................................................................................... 341 Disassembly ............................................................................................... 342 Assembly .................................................................................................... 342 Installation .................................................................................................. 342 Lift Cylinder, Three Stage Mast ............................................................................ 343 Repair ................................................................................................................. 346 Removal ..................................................................................................... 346 Disassembly ............................................................................................... 347 Assembly .................................................................................................... 347 Installation .................................................................................................. 347 Reach Cylinder, 6BWR15 ....................................................................................... 349 Removal .............................................................................................................. 351 Disassembly ........................................................................................................ 352 Inspection ............................................................................................................ 353 Assembly ............................................................................................................ 354 Installation ........................................................................................................... 355 Tilt Cylinder ............................................................................................................. 357 Removal .............................................................................................................. 359 Disassembly ........................................................................................................ 360 Inspection ............................................................................................................ 361 Assembly ............................................................................................................ 362 Installation ........................................................................................................... 363 Removal .............................................................................................................. 365 Disassembly ........................................................................................................ 366 Inspection ............................................................................................................ 367 Assembly ............................................................................................................ 368 Installation ........................................................................................................... 369 Shimming Carriage with Mast on Truck. ............................................................. 377 Repair ................................................................................................................. 379 Removal ..................................................................................................... 379 Disassembly ............................................................................................... 380 Assembly .................................................................................................... 381 Installation .................................................................................................. 383 Lift Chain ............................................................................................................. 384 Lift Chain Adjustment: ................................................................................ 384 Lift Chain Maintenance .............................................................................. 384 Lift Chain Inspection ................................................................................... 384 Lift Chain Replacement .............................................................................. 391 Mast, Three Stage ................................................................................................... 393
  • 12. Table of Contents Toyota 11 2002-08-01 Master Service Manual Shimming Carriage with Mast on Truck. ............................................................. 399 Repair ................................................................................................................. 401 Removal ..................................................................................................... 401 Disassembly ............................................................................................... 402 Assembly .................................................................................................... 403 Installation .................................................................................................. 405 Lift Chain ............................................................................................................. 406 Sideshifter ............................................................................................................... 407 Mounting Instructions .......................................................................................... 409 Installation .................................................................................................. 409 Operation ............................................................................................................ 410 Maintenance ....................................................................................................... 410 Carriage Removal ...................................................................................... 411 Upper Pad Replacement ............................................................................ 411 Lower Pad Replacement ............................................................................ 412 Cylinder ...................................................................................................... 413 Troubleshooting .................................................................................................. 414 No Sideshifting ........................................................................................... 414 Very Slow Sideshifting ............................................................................... 414 Irregular Sideshifting .................................................................................. 415 Single Reach, 6BWR ............................................................................................... 417 Maintenance ....................................................................................................... 419 Inspection ................................................................................................... 419 Adjustment ................................................................................................. 420 Repair ................................................................................................................. 424 Disassembly ............................................................................................... 424 Assembly .................................................................................................... 426 Carriage Bumpers ............................................................................................... 428 Reach Adjustment ...................................................................................... 428 Fork Carriage Pivot Pins ..................................................................................... 430 Carriage Roller Bearings ..................................................................................... 430 Removal ..................................................................................................... 430 Installation .................................................................................................. 430 Removal .............................................................................................................. 432 Inspection ............................................................................................................ 432 Installation ........................................................................................................... 433 Load Backrest ......................................................................................................... 435 Removal .............................................................................................................. 436 Installation ........................................................................................................... 436 Handset Operation .................................................................................................. 437 Operating Modes ................................................................................................ 440 Revert to Previous Settings ................................................................................. 443 Handset Self Test ............................................................................................... 443 Electrical Controllers (Handset) ............................................................................ 445
  • 13. Table of Contents 12 2002-08-01 Master Service Manual Display Screen .................................................................................................... 446 Menu Navigation Key ................................................................................. 446 Data Inc/Dec Key ....................................................................................... 446 Bookmark Keys .......................................................................................... 446 Operation ............................................................................................................ 447 Menu Structure ........................................................................................... 447 Main Menu ................................................................................................. 448 Interface Protocols and Backward Compatibility ........................................ 449 Parameter Changing .................................................................................. 450 Real-Time Monitoring ................................................................................. 450 Reading Faults and Diagnostic History File ............................................... 451 Cloning and Restoring the Previous Programming .................................... 451 Information Displays ................................................................................... 452 Programmer SetUp .................................................................................... 452
  • 14. Warning Symbols F-code Section C-code Version no T-code 001 Toyota 13 2002-08-01 Master Service Manual Warning Symbols Always follow the warnings given in this Instruction Manual and on the truck to avoid accidents and incidents from occurring. 1. Warning Levels Warning levels Warning text is given in four levels and provide information on the risks, describe the consequences, and instruct how to avoid accidents. DANGER Warns that an accident will occur if the instructions are not followed. The consequences are serious personal injury or possibly death, and/or extremely large material damage. WARNING Warns that an accident can occur if the instructions are not followed. The consequences are serious personal injury or possibly death, and/or large material damage. CAUTION Warns that an accident can occur if the instructions are not followed. The consequences are personal injury and/or material damage. NOTE! Marks the risk of and accident or breakdown if the instructions are not followed.
  • 15. 001 Version no T-code F-code Section C-code Prohibitory Symbols 14 2002-08-01 Master Service Manual Prohibitory Symbols NO SMOKING If smoking occurs in situations where a restriction against smoking is stated, a serious accident can occur. OPEN FLAMES PROHIBITED If open flames are used in situations where open flames are prohibited, a serious accident can occur. GENERAL PROHIBITION If the prohibition is ignored, a serious accident can occur. 1. Ordinance Symbols SAFETY SHOES When the directive for safety shoes is given, safety shoes shall always be worn to reduce personal injury. PROTECTIVE GLASSES When the directive for protective glasses is given, protective glasses shall always be worn to reduce personal injury.
  • 16. Safety F-code Section C-code Version no T-code 001 Toyota 15 2002-08-01 Master Service Manual Safety 1. General Safety Do NOT operate or work on truck unless trained, qualified, and authorized to do so and have read the Operator’s Manual. Know the truck controls and what they do. Do NOT operate truck if it needs repair or if it is in any way unsafe.
  • 17. 001 Version no T-code F-code Section C-code Safety 16 2002-08-01 Master Service Manual Operate truck only from the operator’s position. Before working on truck always turn key switch to OFF and disconnect truck’s battery connector (unless this manual states otherwise). Do NOT wear watches, rings, or jewelry when working on truck.
  • 18. Safety F-code Section C-code Version no T-code 001 Toyota 17 2002-08-01 Master Service Manual Follow the scheduled lubrication, maintenance, and inspection steps. Follow exactly the safety and repair instructions in this manual. Do NOT take “shortcuts”. Do NOT Use an open flame near the truck. Do NOT use gasoline or other flammable liquids for cleaning parts.
  • 19. 001 Version no T-code F-code Section C-code Safety 18 2002-08-01 Master Service Manual Clean up any hydraulic fluid, oil, or grease that has leaked or spilled on the floor. Always operate and park truck indoors. Do NOT wash truck with a hose. Do NOT add to or modify truck without written approval from Toyota
  • 20. Battery Safety F-code Section C-code Version no T-code 001 Toyota 19 2002-08-01 Master Service Manual Battery Safety Read, understand and follow procedures, recommendations and specifications in the battery and battery charger manufacturer’s manuals. As a battery is being charged, an explosive gas mixture forms within and around each cell. If the area is not properly ventilated, this explosive gas can remain in or around the battery for several hours after charging. Be sure there are no open flames or sparks in the charging area. An open flame or spark can ignite this gas, resulting in serious damage or injury. Battery electrolyte is a solution of sulfuric acid and water. Battery acid causes burns. Should any electrolyte come in contact with clothing or skin, flush the area immediately with cold water. Should the solution get on the face or in the eyes, flush the area with cold water and get medical help immediately. WARNING WARNING
  • 21. Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
  • 22. 001 Version no T-code F-code Section C-code Battery Safety 20 2002-08-01 Master Service Manual Wear personal protective equipment to protect eyes, face, and skin when checking, handling, or filling batteries. This equipment includes goggles or face shield, rubber gloves (with or without arm shields) and a rubber apron. Make sure a shower and eyewash station are nearby in case there is an accident. A battery gives off explosive gases. Never smoke, use an open flame, or use anything that gives off sparks near a battery.
  • 23. Battery Safety F-code Section C-code Version no T-code 001 Toyota 21 2002-08-01 Master Service Manual Keep the charger area well-ventilated to avoid hydrogen gas concentration. Turn the key switch off before disconnecting the battery from the truck at the battery connector. Do NOT break live circuits at the battery terminals. A spark often occurs at the point where a live circuit is broken. Do NOT lay tools or metal objects on top of battery. A short circuit or explosion could result.
  • 24. 001 Version no T-code F-code Section C-code Battery Safety 22 2002-08-01 Master Service Manual Keep batteries clean. Corrosion causes shorts to the frame and possibly sparks. Keep plugs, terminals, cables, and receptacles in good condition to avoid shorts and sparks. Keep filler plugs firmly in place at all times except when the electrolyte level is checked, when water is added to the cells or when the specific gravity is checked. Make sure vent holes in filler plugs are open to allow gas to escape from the cells. Vent Plug