GUIDE WIRE INSTALLATION

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Maintenance

GUIDE WIRE

INSTALLATI

MTC10, MTC

13 (NTA030SA) [A868,

A872]; MTC

15 (NTA040SA) [A869,

A873]; MT

C18 (NTA040DA) [A870,

A874]; MT

C13 (NTA030SB) [B868];

MTC15 (N

TA035SB) [B869]; OSO30EA [A801];

OSO30EB

[B801]; OSO30EC [C801];

OS/SS03

0BC [B826]; OS/SS030BD [C826];

OS/SS0

30BE [D826]

PART NO. 520371764 2200 YRM 1230

SAFETY PRECAUTIONS

MAINTENANCE AND REPAIR

• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and

that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to

support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift

trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT

TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed

the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to

remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit

needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are

flammable. Be sure to follow the necessary safety precautions when handling these fuels and when

working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the

area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or

serious injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor

or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background.

The CAUTION symbol and word are on yellow background.

Guide Wire Installation Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1

Description .......................................................................................................................................................... 1

Guide Wire Physical Installation .......................................................................................................................... 2

Equipment ........................................................................................................................................................... 11

Specifications ...................................................................................................................................................... 14

Wire Slot and Expansion Loop Specifications................................................................................................. 14

Material and General Specifications ............................................................................................................... 15

System II Wire Guidance Specifications.............................................................................................................. 18

Pre-Installation Information Form ........................................................................................................................ 20

This section is for the following models:

MTC10, MTC13 (NTA030SA) [A868, A872];

MTC15 (NTA040SA) [A869, A873];

MTC18 (NTA040DA) [A870, A874];

MTC13 (NTA030SB) [B868];

MTC15 (NTA035SB) [B869];

OSO30EA [A801];

OSO30EB [B801];

OSO30EC [C801];

OS/SS030BC [B826];

OS/SS030BD [C826];

OS/SS030BE [D826]

2200 YRM 1230 Description

General

This manual has the correct procedures/methods for

installing the guide wire and wire driver for operation of

theYaleWireGuidedVehicles. Theprocedureisina

sequential step format in the order the steps are usually

done. Some steps can be performed out of sequence

if the application and circumstances indicate. Ade-

quate preparation for an economical and durable wire

installation therefore requires a review and complete

understanding of this procedure before initial checking

of the site. A list of required tools, equipment and

supplies, as well as specifications are included in this

manual.

For adjustments of the wire driver, refer to the section

Wire Driver Manual 2200 YRM 1229.

Description

There are several things that must be done before be-

ginning the actual installation of the guide wire. Careful

planning can prevent costly and time consuming mis-

takes. It may be easier and cheaper for the wire in-

staller to repair any minor floor irregularities in the truck

path during guide wire installation. It is best the racks

can be installed and approved by the customer and Yale

Company before the installation of the guide wire. If the

racks cannot be installed before the guide wire instal-

lation, rack location must be referenced to one or more

permanent benchmark points. These points must be

established and agreed upon by the customer and Yale

Company. All dimensions for the guide wire installation

must be referenced to the approved racks or the bench-

marks. When the guide wire path is known, a physical

inspection of the floor must be done by the customer

anddealertoestablishthefollowing:

1. Location of racks or benchmark points. Possible

location of the wire driver.

2. Location of areas of floor to be repaired.

3. Location of all expansion joints and cracks in the

wire path.

4. Location of studs, conduit, rebar, water or drain

lines, rails, or other material in the concrete of the

wire path that will require special procedures during

cutting or installation.

An accurate wire path drawing based on the previously

planned aisle layout must be made by either the cus-

tomer, the dealer, or Yale Company. The purpose of this

wire and rack installation drawing is to plan the contin-

uous wire path of up to 1524 m (5000 ft) per line driver.

The drawing will also be used to show:

1. Dimensions for wire routing.

2. Walls and traffic aisles.

3. Location of wire driver in a visible area.

4. Total estimated wire length.

5. Total saw cut length.

6. Location and type of floor discontinuities.

7. Location of desired expansion loops.

8. Location and capacity of electrical outlets.

9. The location and type of connectors necessary to

connect a garden hose to the cold water source(s).

If possible, the drawing should include a 12.2 m (40 ft)

straight section of guide wire outside the rack aisle for

truck testing and alignment. All dimensions must be ref-

erenced to the approved racks or to the agreed on per-

manent benchmark points and be given in inches or feet

and inches. The drawing must be mutually approved by

the customer and Yale Company.

At least two weeks before the date of installation of the

wire, a pre-installation information form must be com-

pleted by the dealer. At this time, the working hours

will be tentatively scheduled with the customer and the

amount of customer help (if any) will be determined. If

possible, establish cutting hours when customer per-

sonnel and vehicle traffic through the cutting area are

at a minimum. Alternate traffic patterns must be devel-

oped to avoid congestion during installation. See Fig-

ure 2.

Guide Wire Physical Installation 2200 YRM 1230

The amount of normal traffic through the work area, the

number of people close enough to the saw cutting to

require ear protection, protection of electrical and wa-

ter lines from vehicle traffic, and venting for the exhaust

ifagasolinepoweredsawisused,arethingstobecon-

sidered in establishing the working hours. Establish ar-

eas for breaks and lunch for the work party. If neces-

sary, define any off-limit areas and determine security

arrangements for entering and exiting the work site, es-

pecially during odd hours.

At this time, the movement or protection of any material

or equipment in the work area must be agreed to by

the customer. Determine from the customer a suitable

dump site for the slurry from the cutting operation.

Make sure container handling and transportation will be

available for handling the slurry from the installation site

to the dump site. Make sure the floor is smooth enough

for the casters on the 208.2 liter (55 gal) drum of the

vacuum. See Figure 1. Slurry must NOT be dumped

in sewer or storm drains. Make sure the flow from the

water source will not be interrupted during the cutting

operations.

The date and responsibility for installation of the wire

driver must be established at this time. A copy of Wire

Driver Manual 2200 YRM 1229 must be provided.

Makesurethewiredrivercanbeinstalledsothatit

is approximately 1.5 m (5 ft) above the floor (bottom

of box), will be visible during normal operation and is

reasonably protected. It is the customers responsibility

to provide a 115 volt or 230 volt, 1 amp power source

for the wire driver. The wire driver must be installed

using conduit for the guide wire and the power source

per specifications and according to local and national

electrical and building codes. If necessary, the control

module can be removed and stored in a safe place until

all work is completed.

Figure 1. Wet Vacuum

Guide Wire Physical Installation

1. Make sure the work party knows the security ar-

rangements for access to work site. Show them the

location of restrooms and the break and lunch ar-

eas. Make sure they know the location of all off-limit

areas.

2. Locate the power and cold water sources. Provide

protection for the power and water lines if vehicles

will cross lines. Install the pedestrian and other traf-

fic barricades. See Figure 2. Distribute ear pro-

tection devices to customer personnel and cutting

crew. Make sure all material or equipment has been

removed from the area or is protected from the dust

and water of the cutting process.

Figure 2. Traffic Barricades

2200 YRM 1230 Guide Wire Physical Installation

3. Locate the benchmark from which all dimensions

are taken. In the example of Figure 3, the bench-

mark is the column which is flush with the rack face.

If the racks are already installed and have been

checked and approved, measurements can be

taken from the racks. Otherwise, measurements

must be taken from the permanent benchmark

points. Any variation between the actual ware-

house, racks, or guide wire path and the drawing

MUST be resolved BEFORE continuing the layout

and cutting. Wire guided tracks operate in mini-

mum clearance conditions so all changes must be

approved before installation continues.

4. Mark the guide wire reference locations with a felt

tip pen. Using the transit, piano wire, taut string, or

laser beam, mark sufficient points along the path to

allow convenient chalk-line marking. See Figure 4.

5. Now is the time to double check all dimensions

and locations against the guide path installation

drawing. Any discrepancies and all questions must

be resolved between the customer, Yale Company,

and installer.

6. The chalk line must be exactly located over the pre-

viously marked points. See Figure 5. Slight varia-

tions are not allowed due to the critical nature of

wire straightness. The line must be snapped so the

red chalk is highly visible along a continuous path

with no breaks.

Figur

e3. Benchmark

Figure 4. Marking Guide Wire Path

Figur

e 5. "Snapping" Chalk Line

Guide Wire Physical Installation 2200 YRM 1230

7. The entire chalk path must be spray coated us-

ing the specified clear sealer to prevent its being

erased prior to or during cutting of the slot. See

Figure 6.

8. Mark any floor irregularities which require expan-

sion loops or which must have the slot filled with

silicon elastic instead of grout to allow for expan-

sion. Metal within 50.8 mm (2 in.) of the saw cut

must be removed and the area filled with epoxy and

ground flush with the surface. In Figure 7, the two

metal studs are small enough that they were left in

the floor and ground flush with the concrete surface.

The cracks and expansion joint shown were reme-

died by filling the slot with caulking for 101.6 mm

(4 in.) on each side of the discontinuity.

9. ThecrackshowninFigure8hadchippedoutinan

area in the path of the load wheel. The chipped

area had to be ground smooth, cleaned, filled with

epoxy, and ground flush with the surface. Grind all

high spots and fill all low spots where the floor tol-

erance is not within the specification on the instal-

lation drawing.

Figure 6. Spraying Chalk Line

Figure 7. Floor Irregularities

2200 YRM 1230 Guide Wire Physical Installation

Figure 8. Low Spot Filled

10. On a new or unstable floor, expansion loops must

be made at each expansion joint between concrete

pads and at the end of each aisle. Minor cracks,

where the concrete cannot shift, do not need ex-

pansion loops. However, the guide wire must be

coveredwithcaulkingforatleast50.8mm(2.0in.)

on each side of the crack. If vertical loops are used,

the holes must be drilled now. Horizontal loop slots

canbeaddedwithanelectrichandsawafterthe

guide wire slot is cut. The expansion loops must

be made as shown in Figure 23 in the Specifica-

tions section. The areas that have caulking make

the guide wire continuity checking and repairs much

easier.

11. Saw alignment is the most critical step in cutting the

floor. The first cut must be made in a main or cross

aisle where the truck will not need to guide on the

wire. Before turning the saw on, it should be pushed

forward and backward along a 6.1 m (20 ft) length,

and the steering adjusted until it tracks along that

length without deviation. This must be done at the

beginning of each cut. See Figure 9.

12. Turnthesawandwateronandadjustthetravel

speed and water flow. The speed must be gradually

increased until the saw starts to lug down. Reduce

the speed until the blade runs freely. While cutting,

increase the water flow until the water coming out

of the cut slot is clear. Reduce the flow until the

color is a slight milky color. The speed and flow

adjustment can be noted for later reference. The

speed and flow can also very for different areas or

floor composition. The depth of cut (slot depth) will

also decrease with a speed increase or an increase

in concrete hardness or density.

Figure 9. Aligning Saw

Guide Wire Physical Installation 2200 YRM 1230

13. The depth of the slot must be 11.18 mm (7/16

or 0.44 in.) for one wire and 12.70 mm (1/2 or

0.50 in.) for two wires. A standard 3.175 mm (1/8

or 0.125 in.) blade is acceptable. If three or four

wires are planned, the slot must be deep enough

to ensure 6.35 mm (1/4 or 0.25 in.) grout over

the top wire. A diamond blade will hold the slot

depth with only infrequent adjustments for wear.

Measure the depth continually and adjust the saw

as necessary to maintain a depth tolerance of

±1.5875 mm (±1/16 or 0.0625 in.). A gradual tran-

sition is acceptable if the top wire will be covered

with the minimum 6.35 mm (1/4 or 0.25 in.) grout.

The transition must be over a distance of more

than 1.5 m (5 ft).

14. While sawing, constant attention must be on the

saw path. See Figure 10. Every effort must be

made to keep the indicators and blade in-line. Make

sure the slot is within tolerances shown in the Spec-

ifications section. The end of each cut must extend

at least 203.2 mm (8 in.) beyond the actual inter-

section point.

15. The slurry must be vacuumed immediately, to keep

it from re-hardening in the slot. A squeegee and

if necessary, another vacuum is used to keep the

slurry from flowing over the floor. See Figure 11.

16. Saw alignment is critical at all times. If the chalk

line is difficult to see, a flashlight can be used. See

Figure 10.

Figure 10. Keep Saw on Path

Figure 11. Vacuum Slurry Immediately

WARNING

If water is used with the electric hand saw, the saw

MUST have an insulated case and care must be

taken to prevent electrical shock.

17. For short distances, to widen the slot for expan-

sion loops, and to deepen the slot when needed,

an electric hand saw can be used. See Figure 12.

Although this can be a dry cut, a water supply for

cooling and lubrication is better. A water type fire

extinguisher filled with water can be used.

18. No special care is given to the slot after cutting. It

can be left overnight without covering it. If left for

long periods, duct tape can be used to keep the slot

free of dirt.

19. Inspect the entire slot (especially guided sections)

to locate any metal in the slot path that was not

visible at the surface. Rebar, conduit, or pipe are

some examples. If the conduit or pipe are still in

use, an agreement must be made with the customer

on the solution to the problem. Remove any metal

within 50.8 mm (2 in.) of the slot. Fill the area with

epoxy and grind the epoxy flush with the surface.

Cut the slot through the filled area.

20. Just prior to laying the wire, the slot must be cleared

using an ice pick or similar instrument. Then vac-

uum the slot and surrounding area, to make sure

there are no granules left in the slot. See Figure 13.

2200 YRM 1230 Guide Wire Physical Installation

Figure 12.

Electric Hand Saw

Figure 13. Vacuum Slot

21. The wire is installed in the slot directly from the reel.

A blunt instrument is used to press the wire into

the bottom of the slot. The instrument shown in

Figure 14 is a keyhole saw with the blade ground

smooth. If necessary, use pieces of cork or card-

board to keep the wire in the bottom of the saw cut.

It is important for correct guidance that the wire is

kept at the bottom of the saw cut. The cork or card-

board must be a tight fit in the slot to hold the wire

at the bottom of the slot.

22. Whenever the wire passes around the corner, it

must be taped to prevent chafing. An alternative

methodistoprovideanexpansionloopsothewire

passes around the corner only along the short wire

length that will experience very little movement.

See Figure 15.

23. When a splice is needed, the "Western Union" or

equivalent method must be used. These splices

must be made at a point where the truck will not

be guiding. A 101.6 mm (4.0 in.) length of heat

shrinkable tubing is placed on the end of the one

wire. The wire insulation is stripped back 38.1 mm

(1 1/2 or 1.5 in.). Twist the strands of each end and

make the "Western Union" splice. See Figure 16.

Figure 14. Installing the Wire

Figure 15. Loop at Corner

Guide Wire Physical Installation 2200 YRM 1230

Figure 16. Splice

Legend for Figure 16

1. SHRINKABLE TUB

ING

2. WESTERN UNION SPLICE

3. SEALANT

4. SOLDERING IRON

5. SOLDER

6. HEAT GUN

24. Solder the wires together and center the shrinkable

tubing over the splice. Use the heat gun or hold the

soldering iron under the splice to shrink the tubing

around the splice until it is tight. Coat the splice

with the specified sealant. If needed, chisel or saw

theslotsoitiswideenoughforthesplice. See

Figure 16.

25. When the wire is completely installed, leave some

extra length of wire at the wire driver box for con-

venience. If the wire driver is located in a traffic

area, the conduit must be buried. A 50.8 × 50.8 ×

50.8 mm (2 × 2 × 2 in.) hole for the conduit can be

made by drilling, sawing, and chiseling. If located

in a non-traffic area, the guide wire can exit the con-

duit and enter the slot at the floor surface. However,

the end of the conduit and slot must be covered with

grout as shown in Figure 17.

26. The next step is to test the continuity of the wire.

See Figure 18. This must be done before grout-

ing because corrections are difficult to make after

the grout is installed. A voltage/ohmmeter (VOM)

connected to the wire ends will indicate four to five

ohms per 304.8 m (1000 ft) of wire, if the wire has

continuity. An infinity indicates a break in the wire.

A reading of much less than the proper resistance

indicates a short circuit between sections of the

wire. Inspect the total length of the wire to locate

any break(s) or short(s) and make the necessary

repairs. The wire driver control module can be in-

stalled now or as the final step.

27. All cracks and breaks in the floor must have been

previously marked. The entire guide path must be

inspected. Fill the slot using elastic caulking for a

minimum of 50.8 mm (2 in.) each side at all expan-

sion loops, cracks, and over any splices. Fill the slot

flush with the surface. Generally, it is better to use

too much than too little caulking. This step must be

completedbeforegroutingbegins.SeeFigure19.

2200 YRM 1230 Guide Wire Physical Installation

Figure 17. End of Conduit Covered

Figure 18. Testing Wire

Figure 19. Caulking Slot

28. Now the grout can be applied to the entire guide

path. With a resin-mixed grout, the consistency will

be stiff, so pouring is not possible. As shown in Fig-

ure 20, installing the grout with a trowel is required.

If water-mixed grout or thin epoxy is used, a pour-

ing technique is possible. Plastic ketchup or chalk

bottles can be filled and used to squirt the grout into

theslot,whileasecondpersonkeepsthecontain-

ers filled. Another possible technique is to insert

and tape a funnel to one end of a long tube, such

as a golf tube, and tape a small funnel or chalk bot-

tle top to the other end. See Figure 20. Then one

person can hold the small funnel to direct the grout

into the slot, while the second person pours grout

into the large funnel. If the grout begins to harden

and will not pour, dump the batch, clean the tools,

and make a new batch.

29. It is extremely important for the grout to be flushed

with the floor surface. Because the grout hardens

rapidly, only one segment of the guide path must

be grouted at one time. Before moving to the next

segment, the grout must be scraped with a trowel

or spatula and smoothed before it solidifies. See

Figure 21. The length and timing of each segment

will depend on the consistency of the grout. Have a

readily available water supply with 18.93 liter (5 gal)

pails and other supplies to allow a more efficient

process. The 208.2 liter (55 gal) drum for the wet-

dry vacuum can be partially filled with water to rinse

the equipment periodically.

Guide Wire Physical Installation 2200 YRM 1230

Figure 20. Grouting

Figure 21. Smoothing Grout

30. As mentioned previously, the wire driver conduit to

thefloorcanbeeitheraburiedorsurfaceinterface.

AsshowninFigure17,thewiredriverislocated

where no pedestrian or equipment traffic will occur,

so the exposed wire and the end of the conduit is

simply covered with a few inches of grout.

31. The entire floor must be cleaned and swept. See

Figure 22. The guide path will be almost unnotice-

able in the floor. The extent of the cleanup must

be mutually agreed to by the customer and the in-

staller. Generally, a water or mopping cleanup is

the customers responsibility.

32. Now the control module can be installed in its hous-

ing, and the wire continuity checked again. Con-

nect and check the wire driver according to Wire

Driver Manual 2200 YRM 1229.

33. Inspect the installation with the customer so that the

customer knows that the installation is satisfactorily

completed, and wire continuity has been checked.

Figure 22. Sweeping Guide Path

2200 YRM 1230 Equipment

Equipment

Table 1. Equipment

Layout Equipm

ent

At least one 30.5 m (100 ft) tape measure.

Chalk line

Chalk (inclu

ding refills

Red preferre

d, blue acceptable. Yellow or white

NOT acceptab

le since they are not as permanent.

Clear sealer to seal chalk line Clear spray "paints" commonly available in spray

cans work well. Tank type sprayers using bulk

concrete sealer can be used. Sealer must preserve

chalk line before and during cutting of groove.

A normal transit, piano wire or laser beam To ensure straight lines. Sufficient piano wire or

string for the longest aisle can be substituted for the

transit. A laser beam can also be used.

Felt tip (f

ine) marker

Appropria

te color ink for marking reference points

on floor.

Cutting Equipment

A self propelled concrete saw Electric (preferred) or gasoline powered. A

355.6 mm (14 in.) blade capacity and 18

horsepower is preferred. Must have an infinite and

positive depth adjustment and be equipped for water

cooling the blade. Provide extra gasoline, funnel,

and etc. if gasoline powered machine is used.

Two (minimum) general purpose 355.6 mm (14 in.)

diamond blades

One cutting and a minimum of one replacement

or spare. More blades can be required for large

installations. Type of blade can vary depending on

floor composition. A carborundum blade can be

necessary to cut steel plate, rails, or other large

pieces of metal in the floor.

A wet-dry vacuum To pick up slurry before it sets and to clean slot

before installing wire. A vacuum to fit a 208.2 liter

(55 gal) capacity drum mounted on a caster base is

recommended. Smaller wet-dry vacuums can also

be necessary to prevent water flow on the floor.

An electric hand saw with concrete blade Used for short cuts and minor corrections to depth

or straightness. Minimum one spare or replacement

blade.

An electric rotary/hammer hand drill with 3/4 inch

bit capacity

For drilling vertical expansion loop holes.

1/2 and 3/4 inch carbide tipped impact masonry

bits

For rotary/hammer drill.

Electric grinder (right angle) For grinding metal or epoxy flush with the surface.

Carbidegrindingwheel(s) For grinder. Sufficient quantity to complete

installation.

Equipment 2200 YRM 1230

Table 1. Equipment (Continued)

20 amp capacity extension cords Sufficient length(s) to reach furthest point from

power source to equipment.

10.

Standard garden hose For concrete saw blade cooling. Sufficient length to

reach furthest point from water source.

11.

Hose/pipe adapter or connectors To adapt water source outlet to garden hose

connector. Repair connectors to repair the hose if it

is damaged during cutting operation.

12.

Portable water tank For water source to cool hand saw blade. Can be

water type fire extinguisher or garden sprayer filled

with water.

13.

Floor squeegee For moving saw slurry on floor (containment until

removed). Provide extra replaceable squeegee

blades for the squeegee head or sufficient

squeegees to complete the job. The squeegee

blades wear rapidly.

14.

Safety goggles, ear protection, flashlight For saw operator(s). OSHA can require ear

protection for others near saw cutting operation if

cutting is too loud. Flashlight for chalk path visibility.

15.

208.2 liter (55 gal) drum For dumping slurry from vacuum to transport dump

site. Caster base for moving drum.

Wire Installation Tools and Supplies

Wire Sufficient length of wire for all guide paths (no

splices in guided areas), return paths, and test

paths.

Ice pick For scraping, loosening particles in slot before

vacuuming just before wire installation. A keyhole

saw ground smooth or similar tool can be

substituted.

Pliers, wire strippers, solder, and solder gun or iron For making wire splices.

Heat shrinkable tubing, electrical tape, and sealant Sufficient length of specified tubing to insulate

and protect splices ( 101.6 mm (4 in.) minimum

per splice). Tape for protecting wire insulation at

corners. Specified sealant to protect splices.

Commercial heat gun (hot air) To shrink tubing. Soldering iron can be used if there

is enough heat without direct contact to tubing.

Smooth tipped tool Forpressingwireintoslot.Astiffpieceofbentwire

or keyhole saw (ground smooth) will do.

Pieces of cork or thick cardboard Used to keep wire in the bottom of the slot before

grouting. May be unnecessary depending on width

of cut.

Grouting Tools and Supplies

Spec

ified grout

For f

illing slot over wire. Sufficient quantity to finish

job.

2200 YRM 1230 Equipment

Table 1. Equipment (Continued)

Specified caulking For filling over, crack or expansion joints. Sufficient

quantity to finish job.

Caulking gun For dispensing caulking.

Epoxy concrete patching compound For patching, filling, or leveling small areas of the

floor.

Pails or trays For mixing grout or epoxy patch compound. For the

epoxy products, containers must be disposable or

have disposable liners and be in sufficient quantity

to complete job.

Trowels and grout tools For working grout into slots and cracks. For finishing

grout smooth at all floor repairs. A shovel can be

necessary depending on the type of grout.

Plastic ketchup bottles or funnels, chalk bottle tops

and golf tube

For getting grout mix into slot.

Knee pads or kneeling pad Recommended for knee protection during grouting

operation.

Testing Equipment

A volt/ohm

meter (VOM).

Beckman HD

100 Recommended.

Fluke 8020

A acceptable at 6.25 KHz or less

For checki

ng guide wire continuity and wire driver

output. M

eter MUST have a reading resolution

of 100 uV a

nd an RMS accuracy of ±5 percent

at the fre

quency of the wire driver.

Specifications 2200 YRM 1230

Specifications

WIRE SLOT AND EXPANSION LOOP

SPECIFICATIONS

Figure 23 shows the wire slot and expansion loop spec-

ifications.

A. SLOT

B. EXPANSION LOOPS

C. VERTICAL LOOP (PREFERRED METHOD)

D. HORIZONTAL METHOD

E. GROUT OR EPOXY

F. ELASTIC CAULKING

1. CONCRETE

2. SLOT

3. GUIDE WIRE

4. HOLE (12.7 mm (1/2 or 0.5 in.) FOR SINGLE,

19.05 mm (3/4 or 0.75 in.) FOR DOUBLE

5. CRACK

6. EXPANSION JOINT BETWEEN CONCRETE

PADS

Figure 23. Wire Slot and Expansion Loop Specifications

2200 YRM 1230 Specifications

MATERIAL AND GENERAL

SPECIFICATIONS

Table 2 shows the material specifications. Table 3

shows the general specifications.

Table 2. Material Specifications

Material

Specification

Wire 6 AWG, stranded 19/29 copper type B, 0.010 PVC insulation, any color,

1.98.12 mm (5/64 or 0.078 in.) diameter

Suggested vendors:

Beldon 9980

Alpha 1858/19

Newark 27F3223WM or 37F571WM

Solder Tin 60%, lead 40%, non-activated rosin core, 16 gauge

Suggested vendors:

Kester

Ersin Multicore

Newark 33F228, 33F315, 33F217, 81N1591

Duratec TLR6016-1

Heat Shrinkable Tubing 3.175 mm (1/8 or 0.125 in.) diameter, any color, PVC, polyolefin or teflon

Suggested vendors:

Voltrex PVS-008, TTS-514, SST-008, FPS-008

Alpha FIT-221-1/8

Newark 37F6992, 81N2701, 37N1170

Sealant (Wire Splice) Provide splice corrosion protection from moisture, oil, or acid.

Suggested product (equivalent products acceptable):

Spray Tec "Crystal Clear Insulating Acrylic"

Type 32N291 (MIL-TT-0048)

Newark P/N 00Z245

3M "IVI-Spray" Electrical Sealer No. 2530

Suggested vendor:

Newark Electronics Chicago

Graybar

Caulking Must remain elastic and not shrink or dry out.

Suggested product:

5-Star Epoxy Grout (U.S. Grout Corportation)

3-6-M (Dural International Corporation)

ROCKITE Grout

Specifications 2200 YRM 1230

Table 2. Material Specifications (Continued)

Material

Specification

Thin Wall E.M.T. Conduit U.L. approved, galvanized electrical metallic tubing.

Trade size: 1/2 inch

Outside diameter: 0.76 +0.005 inch

Inside diameter: 0.622 inch nominal

Wall thickness: 0.042 inch nominal

Suggested vendors:

Graybar

Thin Wall E.M.T. Fitting Steel insulated throat.

Size: 1/2 inch

Suggested vendors:

Graybar Appleton - TW 50SCI, TW-50-SI 98T050

T & B - 5123, 5131

Raco - 2912, 2122, 1992

Gould - 750B, 720B

Steel City - TC-711, TC-721, TC-741

Bridgeport - 250-I, 230-I, 215-I

O.Z./Gedney - 7050 SIT, 4050 SIT

Table 3. General Specifications

Item or Area

Specification

Wire Pat

See Figu

re 23.

Continu

ous (electrically) loop. 1524 m (5000 ft) maximum.

Straightness Maximum ±3.048 mm (±1/8 or 0.12 in.) deviation from straight in any

3.048 m (10 ft) length in guided aisle (smooth transition). A maximum

deviation change 1.5748 mm (1/16 or 0.062 in.) per 1.524 m (5 ft) and

the maximum deviation between any two random points must not exceed

0.3175 mm (0.0125 in.) in any 0.3048 m (1 ft)of wire run.

Maximum 12.7 mm (1/2 or 0.5 in.) deviation from straight in 3.048 m (10 ft)

length outside guided aisle (smooth transition).

Slot Slot to be 3.175 mm (1/8 of 0.125 in.) wide nominal (with of saw blade).

Slot for single wire must be 11.176 ±1.524 mm (7/16 or 0.44 ±1/16 or

0.062 in.) deep. Slot for double wire must be 12.7 ±1.524 mm (1/2 or 0.5

±1/16 or 0.062 in.) deep. Minimum 6.35 mm (1/4 or 0.25 in.) of specified

grout or caulking over all wires.

Spli

No sp

lice allowed in guided aisle. No splice allowed in expansion loops.

Each

end of wire to have 38.1 mm (1 1/2 or 1.5 in.) insulation removed

and w

ire strands twisted together. "Western Union" type splice required.

Spli

ce must be soldered using specified solder and soldering iron or gun.

Spli

ce must be centered in a 101.6 mm (4 in.) length of specified heat

shr

ink tubing. Tubing to be heated by hot air. No direct flame or hot metal.

Hea

t shrink tubing must be coated after shrinking using specified sealant.

Spl

iced wire must be covered by specified elastic caulking in slot for

50.

8mm(2in.) eachsideofsplice.

Expansion Loops Expansion joints and cracks that can shift and stress the wire must have

vertical or horizontal expansion loops as shown in Figure 23.

2200 YRM 1230 Specifications

Table 3. General Specifications (Continued)

Item or Area

Specification

Floor Flatness Lift Heights

to 6096 mm (240 in.)

Floor flatness of Face F65 is recommended. In the direction for truck

travel, the elevation between any two points separated by 1828.8 mm

(72 in.) will not exceed 4.318 mm (1/6 or 0.17 in.) and will not change

at a rate greater than 3.556 mm (1/7 or 0.14 in.) per 0.3048 m (1 ft) of

travel across the floor. Areas that do not meet the specification must be

corrected (filled or ground) to specification.

Perpendicular to the direction of truck travel, the elevation difference

between any two points separated by 1371.6 mm (54 in.) will not exceed

3.556 mm (1/7 or 0.14 in.) and will not change at a rate greater than

3.556 mm (1/7 or 0.14 in.) per 0.3048 m (1 ft) of travel across the floor.

In any direction, the elevation difference between any two points separated

by 304.8 mm (12 in.) will not exceed 1.778 mm (1/14 or 0.07 in.) and will

not change at a greater rate than 1.778 mm (1/14 or 0.07 in.) per 0.3048 m

(1 ft) of travel across the floor. Areas that do not meet this specification

must be corrected (grounded or filled) to specification.

Sharp discontinuities in truck aisle must be filled or ground so that there is

no jolting of the truck.

Floor Flatness Lift Heights

Above 6096 mm (240 in.)

Floor flatness of a Face F95 is recommended. In the direction of truck

travel, the elevation difference between any two points separated by

1828.8 mm (72 in.) will not exceed 2.794 mm (1/9 or 0.11 in.) and will not

change at a rate greater than 2.032 mm (1/12 or 0.08 in.) per 0.3048 m

(1 ft) of travel across the floor. Areas that do not meet this specification

must be corrected (grounded or filled) to specification.

Perpendicular to the direction of truck travel, the elevation difference

between any two points separated by 1371.6 mm (54 in.) will not exceed

2.54 mm (1/10 or 0.10 in.) and will not change at rate greater than

2.032 mm (1/12 or 0.08 in.) per 0.3048 m (1 ft) of travel across the floor.

In any direction, the elevation difference between any two points separated

by 304.8 mm (12 in.) will not exceed 1.0668 mm (1/24 or 0.042 in.) and

will not change at a rate greater than 1.0668 mm (1/24 or 0.042 in.) per

0.3048 m (1 ft) of travel across the floor. Areas that do not meet this

specification must be corrected (filled or ground) to specification.

Sharp discontinuities in truck aisle must be filled or ground so there is

no jolting of the truck.

Floor Magnetic Condition Guidance sensors respond to a magnetic field from the guide wire.

Therefore, all hard topping or any iron or steel must be evenly distributed

within 609.6 mm (24 in.) on both sides of the guide wire. Wire mesh and

rebar must be at least 101.6 mm (4 in.) below the guide wire.

Other magnetic materials, such as pipes, rails, and drains must be at least

152.4 mm (6 in.) below the guide wire.

Other guide wires in the floor with the same or different frequencies must

be at least 762 mm (30 in.) away from the guide wire in the guide path.

System II Wire Guidance Specifications 2200 YRM 1230

System II Wire Guidance Specifications

Installation Requirements

Specifications

Wire Driver Out

put Requirements

Standard

Frequency

Current

6520 ±10 Hertz

76 to 80 mA

Optional

Frequency

Current

5200 ±8 Hertz

34 to 36 mA

Straightness of Guide Requirements

Maximum Deviation from Straight ±3.0 mm (±0.12 in.) per 3.05 m (10 ft)

Maximum Deviation Change 1.6 mm (0.062 in.) per 1.53 m (5 ft)

Maximum Deviation Between Any Two Points 0.32 mm (0.0125 in.) per 305 mm (1 ft)

Maximum Deviations Per 3.05 m (10 ft) One Deviation.

Floor Flatness Requirements - For Lift Heights to

6096 mm (240 in.)

F65

In Direction of Vehicle Travel *

Maximum Elevation Difference 4.3 mm (1/6 or 0.17 in.) per 1829 mm (72 in.) *

Maximum Elevation Change Rate 3.6mm(1/7or0.14in.) per305mm(1ft)*

At 90 to Direction of Vehicle Travel *

Maximum Elevation Difference 3.6 mm (1/7 or 0.14 in.) per 1372 mm (54 in.) *

Maximum Elevation Change Rate 3.6mm(1/7or0.14in.) per305mm(1ft)*

In Any Other Direction of Vehicle Travel *

Maximum Elevation Difference 1.8 mm (1/14 or 0.07 in.) per 305 mm (1 ft) *

Maximum Elevation Change Rate 1.8 mm (1/14 or 0.07 in.) per 305 mm (1 ft) *

Floor Flatness Requirements - For Lift Heights

Above 6096 mm (240 in.)

F95

In Direction of Vehicle Travel *

Maximum Elevation Difference 2.8 mm (1/9 or 0.11 in.) per 1829 mm (72 in.) *

Maximum Elevation Change Rate 2.1 mm (1/12 or 0.08 in.) per 305 mm (1 ft) *

At 90 to Direction of Vehicle Travel *

Maximum Elevation Difference 2.5 mm (1/10 or 0.10 in.) per 305 mm (1 ft) *

Maximum Elevation Change Rate 2.1 mm (1/12 or 0.08 in.) per 305 mm (1 ft) *

In Any Other Direction of Vehicle Travel *

Maximum Elevation Difference 1.1 mm (1/24 or 0.04 in.) per 305 mm (1 ft) *

Maximum Elevation Change Rate 1.1 mm (1/24 or 0.04 in.) per 305 mm (1 ft) *

Floor Magnetic Condition Requirements

2200 YRM 1230 System II Wire Guidance Specifications

Installation R

equirements

Specifications

Floor Topping All iron or floor steel topping must be evenly distributed

within 610 mm (24 in.) on both sides of the guide wire.

Wire Mesh or Rebar Wire mesh and rebar must be at least 102 mm

(4 in.) below the guide wire.

Other Magnetic Materials - Pipes, Rails, Drains Materials must be at least 152 mm (4 in.) below or

610mm(24in.) tothesideoftheguidewire.

Other Guide Wires With the Same or Different Fre-

quencies

Must be at least 762 mm (30 in.) away from

the guide wire and guide path.

Lift Truck Sp

eed With Guide Path Deviation

Zero Deviation (Load End First Only) 8.8 km/h (5.5 mph) (R30EA only)

32 mm (1.25 in.) Deviation 6 km/h (4 mph) maximum (R30E)

3.6 km/h (2.25 mph) maximum (R30EA)

38 mm (1.50 i

n.) Deviation (R30E only)

3.6km/h(2.

25 mph) maximum

44 mm (1.75 in.) Deviation Traction shutoff

* Segment specification for ALL points within the segment. Segment specifications apply to ALL

areas of the guide path (path of truck travel during guided operation).

Pre-Installation Information Form 2200 YRM 1230

Pre-Installation Information Form

Customer’s Name (Print)

Office Address: (For

correspondence regarding

installation)

Telephone Number:

Installatio

n Address:

Person to contact for access to installation site and other arrangements for the installation:

Name(s) (Print):

Date of Installation:

Working Times for Installation:

Number of customer employees helping during

installation (if any):

Amount and type of normal traffic through installation area:

Alternate patterns for traffic during installation. If possible, note on the drawing or draw a map.

Number of customer employees requiring ear

protection:

Determine what methods will be used to protect electrical and water lines from necessary vehicle traffic (lengths

and number of "ramps").

Determine fittings required and distance from power and water.

Electrical fittings:

Number and lengths of

electrical cords:

Hose fittings required:

Number and lengths of garden hoses:

Exhaust fans needed for gasoline exhaust from gasoline powered saw?

Ye s No

Number needed: Type: Size(s):

Define off-limit areas for people making wire installation:

2200 YRM 1230 Pre-Installation Information Form

Define break, lunch, restroom locations for work party:

Define security arrangements for entering and leaving work site. Person to contact if daily escort is needed.

Name (Print):

Procedures:

Locate and arrange for movement or protection of any customer equipment or material in work area. Customer

agreement to have moved or protected by installation date.

Customer or representative initials:

Determine lo

cation of dump site or provision for disposing of slurry. Slurry must NOT be dumped in sewer or

storm drains

. Path to dump site must be smooth enough for caster travel or equipment available to transport full

55-gallon d

rums.

Establish responsibility of installing power for the wire driver prior to the installation date. Provide customer

a copy of The Wire Driver Manual (Form 599565).

Initials of person responsible:

Determine i

f there are areas of the floor that require repair. Will repairs be done by customer?

Ye s No

Will repairs be done during installation by installation crew?

Ye s No

NOTES

____________________________________________________________

Yale Materials Handling Corp.

1400 Sullivan Dr., Greenville, NC 27834-2011

2200 YRM 1230 6/08 (9/05) Printed in U.S.A.

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