Section 3.Systems Overview

Wire Guidance

Wire Guidance

Wire guidance is a means to automatically steer the lift truck while traveling in an aisle. It offers precise steering at full-speed travel in very narrow aisle (VNA) applications.

A wire guidance system consists of two sub-systems.

•Warehouse-installed equipment includes a guide wire and line driver. The guide wire is in the floor and emits an alternating current (AC) signal at a specific frequency and amplitude generated from the line driver.

•Lift truck-installed equipment includes:

•Two guidance sensors, tractor-end and load-end

•Guidance Manager (GM)

•Steer feedback encoder

•Auto/Manual switch, on operator console

•Associated cables and mounting brackets

The lift truck must learn the amplitude and frequency of the guidance signal to correctly track the guide wire.

NOTE: This manual covers all lift truck-installed equipment. For information on warehouse-installed equipment, refer to PDSS-0051, Raymond Wire Guidance.

To operate wire guidance, refer to the Operator Manual.

Wire Guidance Setup

This procedure should not normally have to be performed. For the lift truck to guide correctly, the following must be true:

•For 5.2 kHz, the current through the guide wire must be 100 mA peak-to-peak ±10%.

•For 6.25 kHz, the current through the guide wire must be 225 mA peak-to-peak ±10%.

Model 5200 High-Level Orderpicker

If the warehouse portion of the guidance system has a different line driver output, refer to “Learn Guide Wire Frequency” on page3-9 .

Publication Number: 1043922B, Revised: 2 Sept 2015

Wire Guidance Setup Procedure

1.Perform the Guidance Parameter Setup to set the distance from wire and heading angle parameters. See “Guidance Parameter Setup” on page3-9.

2.Learn the guide wire frequency. See “Learn Guide Wire Frequency” on page3-9.

3.Learn the guide wire offsets. See “Learn Wire Guidance Offsets” on page3-10.

4.Learn the steer center position. See “Learn Steer Center Position” on page3-10.

Guidance Parameter Setup

1.Connect the FlashWare program to the lift truck.

2.At the prompt on the Main Menu, type s for Setup Configuration Items and press the Enter key.

3.Set the following parameters in the lift truck Configure Menu.

Learn Guide Wire Frequency

NOTE: Make sure the line driver is setup and adjusted correctly.

1.In manual steer mode, position the lift truck to center the tractor end and the load end sensors over the guide wire (±0.75 in. [19 mm]). Make sure the drive unit is centered.

NOTE: The horn chirps at approximately 10 chirps per second when the lift truck is over the guide wire and if the present frequency has been learned previously.

2.Without moving the lift truck, turn the key switch OFF.

3.Enter horn code 3,3: a.Hold down the horn button and turn the key switch ON. Do not release the horn yet. b.Wait for the steering indicator LEDs to stop flashing, and release the horn button. c.Press and release the horn button 3 times. Each time you press the button, an additional Battery Indicator LED lights. d.Wait for the Battery Indicator LEDs to turn OFF. e.Press and release the horn button 3 more times.

NOTE: The lift truck Configure Menu displays the lift cutout threshold only.

NOTE: To change these settings:

•Use the UP and Down arrows to select the options.

•Use the left arrow to decrease values, and the right arrow to increase values.

4.After changing the lift truck configuration: f.Wait for the Battery Indicator LEDs to turn OFF.

•Lift truck restarts automatically.

•Horn beeps when Self-Test is finished.

•Screen returns to the main menu.

5.Type x to save these parameters and exit this menu.

4.Wait 30 seconds for the lift truck to learn the guide wire frequency. During this time, the following occurs:

•The Battery Indicator LEDs scroll up and down.

•The horn may chirp during segments of this procedure.

5.After the Battery Indicator stops scrolling, verify the lift truck has learned the guide wire frequency. Observe the following pattern:

•The horn chirps at approximately 10 chirps per second.

Publication Number: 1043922B, Revised: 2 Sept 2015