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Maintenance
GUIDE WIRE
INSTALLATI
ON
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]
©2008 Yale Materials Handling Corp. i
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.
1
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
2
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
3
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
4
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
5
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.
6
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
7
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.
8
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.
9
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
10
2200 YRM 1230 Equipment
Equipment
Table 1. Equipment
Layout Equipm
ent
1.
At least one 30.5 m (100 ft) tape measure.
2.
Chalk line
3.
Chalk (inclu
ding refills
Red preferre
d, blue acceptable. Yellow or white
NOT acceptab
le since they are not as permanent.
4.
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.
5.
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.
6.
Felt tip (f
ine) marker
Appropria
te color ink for marking reference points
on floor.
Cutting Equipment
1.
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.
2.
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.
3.
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.
4.
An electric hand saw with concrete blade Used for short cuts and minor corrections to depth
or straightness. Minimum one spare or replacement
blade.
5.
An electric rotary/hammer hand drill with 3/4 inch
bit capacity
For drilling vertical expansion loop holes.
6.
1/2 and 3/4 inch carbide tipped impact masonry
bits
For rotary/hammer drill.
7.
Electric grinder (right angle) For grinding metal or epoxy flush with the surface.
8.
Carbidegrindingwheel(s) For grinder. Sufficient quantity to complete
installation.
11
Equipment 2200 YRM 1230
Table 1. Equipment (Continued)
9.
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
1.
Wire Sufficient length of wire for all guide paths (no
splices in guided areas), return paths, and test
paths.
2.
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.
3.
Pliers, wire strippers, solder, and solder gun or iron For making wire splices.
4.
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.
5.
Commercial heat gun (hot air) To shrink tubing. Soldering iron can be used if there
is enough heat without direct contact to tubing.
6.
Smooth tipped tool Forpressingwireintoslot.Astiffpieceofbentwire
or keyhole saw (ground smooth) will do.
7.
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
1.
Spec
ified grout
For f
illing slot over wire. Sufficient quantity to finish
job.
12
2200 YRM 1230 Equipment
Table 1. Equipment (Continued)
2.
Specified caulking For filling over, crack or expansion joints. Sufficient
quantity to finish job.
3.
Caulking gun For dispensing caulking.
4.
Epoxy concrete patching compound For patching, filling, or leveling small areas of the
floor.
5.
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.
6.
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.
7.
Plastic ketchup bottles or funnels, chalk bottle tops
and golf tube
For getting grout mix into slot.
8.
Knee pads or kneeling pad Recommended for knee protection during grouting
operation.
Testing Equipment
1.
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.
13
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
14
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
1.
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
2.
Solder Tin 60%, lead 40%, non-activated rosin core, 16 gauge
Suggested vendors:
Kester
Ersin Multicore
Newark 33F228, 33F315, 33F217, 81N1591
Duratec TLR6016-1
3.
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
4.
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
5.
Caulking Must remain elastic and not shrink or dry out.
Suggested product:
G.E. Silastic Silicone or equivalent
6.
Grout Must not shrink. Can be water mix "mortar" type or epoxy.
Suggested product:
5-Star Epoxy Grout (U.S. Grout Corportation)
3-6-M (Dural International Corporation)
ROCKITE Grout
15
Specifications 2200 YRM 1230
Table 2. Material Specifications (Continued)
Material
Specification
7.
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
8.
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
1.
Wire Pat
h
See Figu
re 23.
Continu
ous (electrically) loop. 1524 m (5000 ft) maximum.
2.
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).
3.
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.
4.
Spli
ce
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.
5.
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.
16
2200 YRM 1230 Specifications
Table 3. General Specifications (Continued)
Item or Area
Specification
6.
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.
7.
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.
8.
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.
17
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
18
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).
19
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:
20
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
21
NOTES
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22
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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