Yale B868 (MTC10-MTC13-MTC13LWB [NTA030SB]) Service Manual - PDF DOWNLOAD

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Manual Title

520371764

Guide Wire Installation

520371765

Wire Driver manual

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524275577

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520371764

Guide Wire Installation Section B868/B869........... Complete PDF

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Maintenance

GUIDE WIRE INSTALLATION 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]

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................................................................................................................................................................

Description ..........................................................................................................................................................

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

Equipment ...........................................................................................................................................................

Specifications ......................................................................................................................................................

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

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

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

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

1 1 2 11 14 14 15 18 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 the Yale Wire Guided Vehicles. The procedure is in a 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. Adequate 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 beginning the actual installation of the guide wire. Careful planning can prevent costly and time consuming mistakes. It may be easier and cheaper for the wire installer 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 installation, 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 benchmarks. When the guide wire path is known, a physical inspection of the floor must be done by the customer and dealer to establish the following: 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 customer, the dealer, or Yale Company. The purpose of this wire and rack installation drawing is to plan the continuous 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 referenced to the approved racks or to the agreed on permanent 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 completed 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 personnel and vehicle traffic through the cutting area are at a minimum. Alternate traffic patterns must be developed to avoid congestion during installation. See Figure 2.

1

Guide Wire Physical Installation 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 water lines from vehicle traffic, and venting for the exhaust if a gasoline powered saw is used, are things to be considered in establishing the working hours. Establish areas for breaks and lunch for the work party. If necessary, define any off-limit areas and determine security arrangements for entering and exiting the work site, especially during odd hours.

2200 YRM 1230 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.

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.

Make sure the wire driver can be installed so that it

Figure 1. Wet Vacuum

Guide Wire Physical Installation 1. Make sure the work party knows the security arrangements for access to work site. Show them the location of restrooms and the break and lunch areas. 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 traffic barricades. See Figure 2. Distribute ear protection 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 benchmark 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 warehouse, racks, or guide wire path and the drawing MUST be resolved BEFORE continuing the layout and cutting. Wire guided tracks operate in minimum 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 previously marked points. See Figure 5. Slight variations 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.

Figure 3. Benchmark

Figure 4. Marking Guide Wire Path

Figure 5. "Snapping" Chalk Line

3

Guide Wire Physical Installation

2200 YRM 1230

7. The entire chalk path must be spray coated using 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 expansion loops or which must have the slot filled with silicon elastic instead of grout to allow for expansion. 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 remedied by filling the slot with caulking for 101.6 mm (4 in.) on each side of the discontinuity.

9. The crack shown in Figure 8 had chipped out in an 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 tolerance is not within the specification on the installation drawing.

Figure 6. Spraying Chalk Line

Figure 7. Floor Irregularities

4

2200 YRM 1230

Guide Wire Physical Installation also decrease with a speed increase or an increase in concrete hardness or density.

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 expansion loops. However, the guide wire must be covered with caulking for at least 50.8 mm (2.0 in.) on each side of the crack. If vertical loops are used, the holes must be drilled now. Horizontal loop slots can be added with an electric hand saw after the guide wire slot is cut. The expansion loops must be made as shown in Figure 23 in the Specifications 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. Turn the saw and water on and adjust the travel 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

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 transition 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 Specifications section. The end of each cut must extend at least 203.2 mm (8 in.) beyond the actual intersection 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 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 expansion 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.

Figure 10. Keep Saw on Path

6

20. Just prior to laying the wire, the slot must be cleared using an ice pick or similar instrument. Then vacuum 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 method is to provide an expansion loop so the wire 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 12. Electric Hand Saw

Figure 14. Installing the Wire

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 cardboard 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 cardboard must be a tight fit in the slot to hold the wire at the bottom of the slot.

Figure 15. Loop at Corner

22. Whenever the wire passes around the corner, it must be taped to prevent chafing. An alternative

7

Guide Wire Physical Installation

2200 YRM 1230 Legend for Figure 16 1.

2.

3.

4.

5.

6.

SHRINKABLE TUBING WESTERN UNION SPLICE SEALANT SOLDERING IRON SOLDER 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 the slot so it is wide enough for the splice. See Figure 16.

25. When the wire is completely installed, leave some extra length of wire at the wire driver box for convenience. 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 conduit 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 grouting 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 installed 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 expansion 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 completed before grouting begins. See Figure 19.

Figure 16. Splice

8

2200 YRM 1230

Guide Wire Physical Installation

Figure 19. Caulking Slot

Figure 17. End of Conduit Covered

Figure 18. Testing Wire

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

If water-mixed grout or thin epoxy is used, a pouring technique is possible. Plastic ketchup or chalk bottles can be filled and used to squirt the grout into the slot, while a second person keeps the containers 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 bottle 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 wetdry vacuum can be partially filled with water to rinse the equipment periodically.

9

Guide Wire Physical Installation

2200 YRM 1230 30. As mentioned previously, the wire driver conduit to the floor can be either a buried or surface interface.

As shown in Figure 17, the wire driver is located 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 unnoticeable in the floor. The extent of the cleanup must be mutually agreed to by the customer and the installer. Generally, a water or mopping cleanup is the customers responsibility.

32. Now the control module can be installed in its housing, and the wire continuity checked again. Connect and check the wire driver according to Wire Driver Manual 2200 YRM 1229.

Figure 20. Grouting

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

Figure 21. Smoothing Grout

10

2200 YRM 1230

Equipment

Equipment Table 1. Equipment Layout Equipment 1.

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

2.

Chalk line

3.

Chalk (including refills

Red preferred, blue acceptable. Yellow or white NOT acceptable 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 (fine) marker

Appropriate 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.

Carbide grinding wheel(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

For pressing wire into slot. A stiff piece of bent wire 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.

12

Specified grout

For filling slot over wire. Sufficient quantity to finish job.

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/ohmmeter (VOM).

Beckman HD 100 Recommended.

Fluke 8020A acceptable at 6.25 KHz or less

For checking guide wire continuity and wire driver output. Meter MUST have a reading resolution of 100 uV and an RMS accuracy of ±5 percent at the frequency 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 specifications.

A. SLOT B. EXPANSION LOOPS C. VERTICAL LOOP (PREFERRED METHOD)

D. HORIZONTAL METHOD E. GROUT OR EPOXY F. ELASTIC CAULKING

1.

2.

3.

4.

5. CRACK 6. EXPANSION JOINT BETWEEN CONCRETE PADS

CONCRETE SLOT GUIDE WIRE HOLE (12.7 mm (1/2 or 0.5 in.) FOR SINGLE, 19.05 mm (3/4 or 0.75 in.) FOR DOUBLE

Figure 23. Wire Slot and Expansion Loop Specifications

14

2200 YRM 1230

Specifications

MATERIAL AND GENERAL SPECIFICATIONS Table 2 shows the material specifications. shows the general specifications.

Table 3

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 Path

See Figure 23.

Continuous (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.

Splice

No splice 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 wire strands twisted together. "Western Union" type splice required.

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

Splice must be centered in a 101.6 mm (4 in.) length of specified heat shrink tubing. Tubing to be heated by hot air. No direct flame or hot metal.

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

Spliced wire must be covered by specified elastic caulking in slot for 50.8 mm (2 in.) each side of splice.

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 Output 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 Maximum Deviation Change Maximum Deviation Between Any Two Points Maximum Deviations Per 3.05 m (10 ft) Floor Flatness Requirements - For Lift Heights to 6096 mm (240 in.)

±3.0 mm (±0.12 in.) per 3.05 m (10 ft) 1.6 mm (0.062 in.) per 1.53 m (5 ft) 0.32 mm (0.0125 in.) per 305 mm (1 ft) One Deviation.

F65

In Direction of Vehicle Travel * Maximum Elevation Difference Maximum Elevation Change Rate

4.3 mm (1/6 or 0.17 in.) per 1829 mm (72 in.) * 3.6 mm (1/7 or 0.14 in.) per 305 mm (1 ft) *

At 90 to Direction of Vehicle Travel * Maximum Elevation Difference Maximum Elevation Change Rate

3.6 mm (1/7 or 0.14 in.) per 1372 mm (54 in.) * 3.6 mm (1/7 or 0.14 in.) per 305 mm (1 ft) *

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 Maximum Elevation Change Rate

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

Installation Requirements Floor Topping Wire Mesh or Rebar Other Magnetic Materials - Pipes, Rails, Drains Other Guide Wires With the Same or Different Frequencies

System II Wire Guidance Specifications

Specifications All iron or floor steel topping must be evenly distributed within 610 mm (24 in.) on both sides of the guide wire.

Wire mesh and rebar must be at least 102 mm (4 in.) below the guide wire.

Materials must be at least 152 mm (4 in.) below or 610 mm (24 in.) to the side of the guide wire.

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

Lift Truck Speed With Guide Path Deviation Zero Deviation (Load End First Only) 32 mm (1.25 in.) Deviation 38 mm (1.50 in.) Deviation (R30E only) 44 mm (1.75 in.) Deviation

8.8 km/h (5.5 mph) (R30EA only) 6 km/h (4 mph) maximum (R30E) 3.6 km/h (2.25 mph) maximum (R30EA) 3.6 km/h (2.25 mph) maximum 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: Installation 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?

Yes

No

Number needed:

Type:

Define off-limit areas for people making wire installation:

20

Size(s):

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 location 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 drums.

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

Yes

No

Will repairs be done during installation by installation crew?

Yes

No

21

NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

22

Yale Materials Handling Corp.

1400 Sullivan Dr., Greenville, NC 27834-2011

2200 YRM 1230

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

Maintenance

WIRE DRIVER MANUAL 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]

PART NO. 520371765

2200 YRM 1229

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.

Wire Driver Manual

Table of Contents

TABLE OF CONTENTS General................................................................................................................................................................

Description ..........................................................................................................................................................

Installation Procedure..........................................................................................................................................

Checks and Adjustments.....................................................................................................................................

Checks ............................................................................................................................................................

Adjustments ...................................................................................................................................................

Troubleshooting ...................................................................................................................................................

Wire Driver Troubleshooting ............................................................................................................................

Guide Wire Troubleshooting ............................................................................................................................

Guide Wire Repair...........................................................................................................................................

Short Circuit Repair ....................................................................................................................................

Open Circuit Repair ....................................................................................................................................

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

1 1 3 4 4 6 7 7 8 9 9 9 12

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 1229

Description

General This manual has a description, installation instructions, test and adjustment procedures, troubleshooting for the wire driver, and troubleshooting procedure for locating a break in the guide wire.

Refer to the section Guide Wire Installation 2200 YRM 1230 for information on the guide wire installation.

Description This wire driver is designed to supply the guide signal for Yale wire guidance trucks. Provisions for adjusting the signal frequency and amplitude permit using the wire driver with other truck guidance systems. The wire driver generates a signal between 600 Hz and 12.85 KHz. The frequency can be selected in 50 Hz steps using the frequency select switches. See Figure 1.

A guide wire up to 1524 m (5000 ft) is buried in the floor and connected to the wire driver. The guide wire acts as a conductor for the guide signal that produces a magnetic field which is sensed by the trucks guidance system. The guidance system receives the signal and steers the truck to follow the guide wire. The guide wire current is 78 ±2.0 mA RMS. The standard signal frequency is 6250 ±10 Hz and is factory set. Another common frequency is 5.2 KHz ±8 Hz at guide wire current of 35 ±1 mA RMS. The wire driver operates on 115 volts or 230 volts AC. Self contained backup batteries will automatically operate the unit for approximately four hours. The wire driver is normally operated on the AC power continuously, even when a guide signal is not needed. This prevents the automatic battery operation from discharging the batteries. It also keeps the charging circuit operating so the batteries have a full charge.

The major parts of the wire driver are as follows: • Case with hinged cover and fault lamp - The case protects the electronic circuitry. The fault lamp indicates that the unit is operating on the backup batteries.

• Rechargeable batteries - Provide backup power.

• Power circuit board - The power board provides the correct voltages to the logic board and keeps the batteries charged.

• Logic circuit board - The logic board produces the signal for the guide wire.

The power board has three 1 Amp fuses. Fuse 1 is in the AC source line between the power terminal strip and the primary winding of the transformer. Fuse 2 and Fuse 3 are in the plus and minus DC output lines.

The power board also has three LEDs. LED 1 (green) indicates that the power board has AC power voltage at the secondary of the transformer. LEDs 2 and 3 (red) illuminate when there is plus and minus DC available to the logic board (switch S1 is ON).

The logic board has two red LEDs and a 1 Amp fuse.

LED 1 is an adjustment indicator for setting the current "window". LED 2 is the fault lamp mounted on the door of the wire driver. The fuse is a ground loop protector.

1

Description

2200 YRM 1229

A. FRONT 1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

DOOR FAULT LAMP INTERLOCK SWITCH AC OUTLET TERMINAL STRIP FREQUENCY SELECT SWITCHES CASE LOGIC BOARD LED 1 (LOGIC BOARD) FUSE 1 (1 AMP, LOGIC BOARD) GUIDE WIRE TERMINAL STRIP CAPACITOR C31 POWER BOARD

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

FUSE 2 (1 AMP, POWER BOARD) LED 2 (POWER BOARD) DC POWER SWITCH S1 LED 3 (POWER BOARD) FUSE 3 (1 AMP, POWER BOARD) GUIDE WIRE CONDUIT BATTERIES POWER SOURCE CONDUIT LED 1 (POWER BOARD) 115/230 VOLT AC SELECT SWITCH S2 FUSE 1 (1 AMP, POWER BOARD) SPECIFICATION LABEL

Figure 1. Wire Driver

2

2200 YRM 1229

Installation Procedure

Installation Procedure 1. Install 16 AWG stranded 19/29 type B 0.010 PVC insulated guide wire in the floor according to Guide Wire Installation 2200 YRM 1230.

2. Install 115 VAC or 230 VAC 60/50 Hz power source using EMT or rigid tubing (conduit) and 12.7 mm (0.50 in.) insulated throat connectors. The wire driver power requirement is less than 1 Amp. Install the power according to the national and local electrical and building codes. The wire driver end of the AC power source line must be installed for easy connection to the wire driver. The wire driver must be mounted at an accessible height above the floor for ease of maintenance and for visibility of the fault lamp.

WARNING Make sure the AC power source (main supply) is OFF before installing the wire driver.

3. Install the wire driver so the bottom of the box is approximately 1.5 m (5.0 ft) from the floor and is in an area that is reasonably protected. The fault lamp must also be visible during normal operations.

The door hinge is on the left side. Flanges at the top and bottom of the case have holes for nails or screws. The conduit for the AC power source installs at the left hole in the bottom of the case. Make sure that the 115/230 switch is set to 115 for a 115 volt AC power source and 230 for a 230 volt AC power source. Connect the AC L1 to the top terminal of the AC terminal strip. Connect the neutral/ground to the grounding screw on the side wall of the case. Connect the L2 to the bottom terminal.

4. The frequency select switches (8 switch set) on the logic board sets the frequency of the wire driver.

The switch sets in Figure 2 are shown set for frequencies of 6.25 and 5.2 KHz. The eight switches each have a specific value as shown in Figure 2.

The switch to the far left has a value 128 (up). The next switch to the right has the value of 64 (up). If the switch is in the OFF (down) position, it has no (0) value.

WARNING Make sure the AC power source is set to OFF at the source (circuit breaker) before setting the frequency select switches.

A. SHOWN SET FOR 6.25 KHZ B. SHOWN SET FOR 5.2 KHZ Figure 2. Frequency Select Switches 5. To set the wire driver for a frequency of 6.25 KHz, locate the frequency select switches (on the logic board to the right of the interlock switch near the hinge) and proceed as follows: a. Multiply the frequency (in KHz) by 20.

6.25 × 20 = 125 b. Subtract 2.

125 2 = 123 c. Determine if the first (left most) switch value (128) is greater than the calculated value of Step b (123 for this frequency). If so, set the switch to 0 (down). If not, set the switch to 128 (up).

If the switch value is NOT greater than the calculated value, subtract the switch value from the calculated value and continue to the next step.

If the calculated value of Step b was 130, this remaining value would be 2 (130 128 = 2).

For this frequency, the switch value is NOT greater, so the switch is set to 0. Since we have not subtracted a switch value from the calculated value, the remainder is still the calculated value (123).

3

Checks and Adjustments

2200 YRM 1229

d. Determine if the switch value of the next switch (64) is greater than the remaining value of Step c (64 is NOT greater than 123). If switch value is greater, set the switch to 0 (down).

If the switch value is NOT greater (as for this frequency), set the switch to 64 (up), subtract the switch value from the remainder (123 64 = 59) and continue to the next step.

h. Next switch value (4) IS greater than the remaining value. Set switch to 0 (down) and continue. i.

Next switch value (2) is NOT greater than the remaining value (still 3). Set switch to 2 (up) and subtract.

3 2=1

e. Next switch value (32) is NOT greater than the remaining value (59). Set switch to 32 (up) then subtract.

59 32 = 27

j.

Next switch value (1) is NOT greater than the remaining value (1). Set switch to 1 (up).

f.

Next switch value (16) is NOT greater than the remaining value (27). Set switch to 16 (up) and subtract.

27 16 = 11

g. Next switch value (8) is NOT greater than the remaining value (11). Set switch to 8 (up) and subtract.

11 8 = 3.

6. To find an unknown frequency of a wire driver: 1. Add the switch positions.

0 + 64 + 32 = 16 + 8 + 0 + 2 + 1 = 123 2. Add 2 to the value.

123 + 2 = 125 3. Divide the result by 20.

125 ÷ 20 = 6.25 KHz The final result is the frequency in KHz.

Checks and Adjustments CHECKS NOTE: These checks require a digital volt/ohmmeter that has an AC RMS reading resolution of 100 uV and ±5 percent accuracy at the frequency of the wire driver.

One such meter is the Beckman model HD100. The Fluke model 8020A is acceptable at 6.25 KHz or less.

NOTE: If any of the checks in this procedure fail, refer to the Troubleshooting section.

1. Verify AC is OFF at the source (fuse or breaker panel). Carefully remove the two plugs CP1 and CP2 from the power board. See Figure 3. Verify that the AC select switch S2 is properly set for the AC supply voltage (115 volts or 230 volts).

WARNING Do Not touch the terminal strip for the AC power source during the following tests.

2. Turn the AC power ON at the source (circuit breaker or fuse). Pull the door interlock switch button out until it locks in place. This connects the AC voltage to the power board after the wire driver door is opened. Check that the power board LED 1 (green) is ON. Set the S1 toggle switch to the right (ON).

Check that the LED’s 2 and 3 are ON.

4

3. Use the voltmeter to check for 15 ±0.2 volts DC at CP2 between pins 1 (+) and 2 ( ) and between pins 2 (+) and 3 ( ) (total 30 volts DC). Check for 20 volts AC between pins 2 and 4.

4. Turn the AC power OFF by pushing in and releasing the door interlock switch. LED 1 will be OFF. Install the 3-pin battery connector into CP1. Check for 13.2 ±0.6 volts DC at CP2 between pins 1 (+) and 2 ( ) and between pins 2 (+) and 3 ( ).

5. Set switch S1 toggle switch to OFF and connect the 4-pin connector at CP2. Set S1 toggle switch to ON and check that the fault lamp (mounted on the outside of the door) is flashing.

WARNING Turn the AC power OFF at the breaker panel during this test.

6. Set S1 toggle switch to OFF. Disconnect both ends of the guide wire from the logic board terminal strip TS1. Determine the guide wire length and check for 4 to 5 ohms resistance per 305 m (1000 ft) of guide wire. If not correct, refer to the Troubleshooting section.

2200 YRM 1229

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

Checks and Adjustments

FAULT LAMP (LED 2 LOGIC BOARD) INTERLOCK BUTTON FREQUENCY SELECT SWITCHES LOGIC BOARD R89 CALIBRATION ADJUST TP2 R47 CURRENT ADJUST R78 OUTPUT AMPLITUDE ADJUST TP1 R62 CURRENT WINDOW ADJUST LED 1 TERMINAL STRIP TS1

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

CAPACITOR C31 TP3 TP4 TOGGLE SWITCH S1 CP2 + DC (PIN 1) COMMON (PIN 2) DC (PIN 3) AC (PIN 4) 15 OHM, 10 WATT RESISTOR (LOAD) OSCILLOSCOPE DIGITAL VOLTMETER

Figure 3. Wire Driver Adjustments

5

Checks and Adjustments

ADJUSTMENTS Refer to Figure 3 for component locations.

CAUTION If the wire driver is operating correctly, do NOT make any adjustments.

NOTE: These adjustments require a digital volt/ohmmeter that has an AC RMS reading resolution of 100 uV and ±5 percent accuracy at the frequency of the wire driver. One such meter is the Beckman model HD100.

The Fluke model 8020A is acceptable at 6.25 KHz or less.

1. Verify that the frequency select switches are properly set or follow the setup procedure in the Installation Procedure.

2. Disconnect both ends of the guide wire from the terminal strip and measure the resistance of the guide wire. If the resistance is greater than 16.8 ohms for 6.25 KHz or 37.4 ohms for 5.2 KHz, connect the guide wire to terminals 2 and 3 on the terminal strip.

If the reading is less than 16.8 ohms for 6.25 KHz or 37.4 ohms for 5.2 KHz, connect the guide wire to terminals 3 and 4 on the terminal strip. If the reading is 0 ohms (short circuit) or infinity (open circuit), refer to the Troubleshooting section.

3. Make sure there is a 715P capacitor connected to terminals 1 and 5 of the terminal strip. A typical value for this capacitor is 0.33 ufd, 400 volts DC. Turn the AC power ON at the circuit breaker panel.

Use the procedures in Step 4 through Step 8 to adjust the logic board for the correct signal current.

6

2200 YRM 1229 4. Connect the digital meter between TP2 (current sense) and TP1 (common). Set the meter to the 200 mV DC range. Adjust R47 fully counterclockwise. Pull the interlock switch to set the AC power ON. 5. Adjust R78 (output amplitude) fully clockwise. Adjust R47 (current adjustment) for a 156 mV DC (156 mA wire current) reading on the voltmeter.

6. Adjust R78 to fully counterclockwise. Adjust R78 clockwise until the reading on the meter (TP2) does not increase. Adjust R78 another 1/4 turn clockwise.

For 6.25 KHz: Adjust R47 (current adjustment) for a 78 ±3.0 mV DC reading on the voltmeter. 78 mV is 0.078 volts. This equals 78 mA wire current.

For 5.2 KHz: Adjust R47 (current adjustment) for a 35 ±1.0 mV DC reading on the voltmeter. 35 mV is 0.035 volts. This equals 35 mA wire current.

7. Connect the digital meter between TP3 (AC output) and TP1 (common). Set the meter scale to 20 volts AC. If the meter reading is greater than 6.1 volts AC, connect the guide wire between terminals 2 and 3.

If the guide wire is already connected to terminals 2 and 3, the guide wire is too long to be driven by one driver. If the meter reading exceeds 6.1 volts AC after moving the guide wire to terminals 2 and 3, the guide wire is to long to be driven by one driver.

Contact service for the correct installation.

8. Adjust R62 (current window) until LED 1 on the logic board and the fault lamp (LED 2) are OFF (center of window).

2200 YRM 1229

Troubleshooting

Troubleshooting WIRE DRIVER TROUBLESHOOTING Table 1 shows the wire driver troubleshooting.

Table 1. Wire Driver Troubleshooting Problem Step 2 in the section Checks is not correct.

Possible Cause Verify that the AC supply is correct and the power board line switch S2 is properly set for the AC source voltage (115 volts or 230 volts).

Turn AC power OFF at the source. Check fuse 1 on the power board.

Check the wires and connections between the power source terminal strip, the interlock switch, and the power board.

If these checks are good, replace the power board.

Step 3 of Checks is not correct. Check fuse 2 and 3 on the power board.

Check that S1 toggle is set to the ON position (right).

If LEDs 2 and 3 are ON and the AC source is correct, replace the power board.

Step 4 of Checks is not correct. Batteries are discharged or damaged. To recharge the batteries, connect the 3 pin battery connector into CP1 on the power board and turn the AC power ON for 4 or more hours. Replace the batteries if they are damaged.

With AC power OFF, check the wires and connections between the batteries and the 3 pin plug. If the batteries, wires, and connections are good, replace the power board.

Step 5 of Checks is not correct. Check the wire and plug (CP2) between the power and logic boards. Make sure the AC power is OFF at the source before making checks or repairs.

Check the wiring and connections between the power and logic board and fault lamp. If the wiring is OK, remove the lens and reverse the fault lamp in the socket.

If these checks are good, replace the logic board.

Step 6 of Checks is not correct. Check fuse 1 (1 Amp) on the logic board.

Refer to Guide Wire Troubleshooting.

Wire driver will not adjust correctly.

If the output current level is not adjustable, check that all connections are correct in Figure 3 and as described in the Installation Procedure and Checks and Adjustments. Make sure that the volt/ohmmeter and oscilloscope are the correct type. Refer to the NOTE in Checks and Adjustments.

Check all associated wiring between the logic board and power board.

Check that the frequency select switches are correctly set.

If all checks are good, replace the logic board.

7

Troubleshooting

GUIDE WIRE TROUBLESHOOTING NOTE: Most of the guide wire troubles are from a break in the guide wire (open circuit) usually at a crack or expansion joint. Use the following procedure to find a break in the guide wire.

If Step 6 in the Checks is not correct, the guide wire has an open or short circuit. An open circuit will have an infinite reading in Step 6. A short circuit will have a low resistance reading. The ready will usually be much less than 4 to 5 ohms per 305 m (1000 ft) of guide wire.

Short circuits are rare occurrences and usually occur on the return lines where two wires are in the same slot.

Open circuits usually occur at expansion joints, cracks, or other breaks in the concrete. The following procedure has the steps necessary to find an open circuit.

2200 YRM 1229 slot. If the guide wire installation drawing is available, locating the "caulk" areas will be easier. An area for each "half" of the loop, as close as possible to the wire driver, must be found. See Figure 4 points 1 and 2.

4. Check for low resistance reading at each location of Step 3 (points 1 and 2 of Figure 4). Carefully push the "needle" of the tool through the elastic caulking and insulation of the guide wire. Set the ohmmeter to a low scale (R × 1 or R × 0.5). Measure the resistance between the "needle" of the tool and a floor stud of a rack support. One location will normally have an infinite reading. The other location will normally have a low resistance reading. The location that has the low resistance is the "half" of the guide wire loop that has the ground connection (point 2 of Figure 4).

WARNING Make sure that there are no trucks operating on any part of the guide wire before troubleshooting or repairing the guide wire. Personal injury or equipment damage can occur if trucks are operating.

Make sure the AC power is OFF at the source (circuit breaker OFF).

1. Open the door of the wire driver, set switch S1 on the power board OFF and disconnect both ends of the guide wire from the logic board terminals TS1.

See Figure 4. Check that the insulation of the guide wire is not cut where the ends enter the wire driver case. Use a jumper wire to connect either end of the guide wire to the bottom left (-) battery terminal (battery common - ground) or TP1.

2. Get a sharp ice pick or other tool similar to a heavy duty needle to penetrate the elastic caulking and guide wire insulation.

NOTE: To locate the break in the guide wire, we must know which "half" of the guide wire is the grounded half.

Step 3 and Step 4 will identify the grounded half of the guide wire.

3. Determine which "half" of the guide wire loop has the ground connection at the wire driver. Locate an area that has caulking and has only one wire in the

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CAUTION Fill each "needle" hole with caulking after the "needle" is removed to prevent moisture from entering the hole.

5. Locate a point on the guide wire that is near the center of the guide wire loop. Check the resistance at this point (point 3 of Figure 4). A low resistance reading indicates that the break must be between points 1 and 3 as in the example in Figure 4. An infinity reading at point 3 would indicate a break between points 2 and 3.

6. Locate a point approximately half way between points 1 and 3. Check the resistance at this point (point 4 of Figure 4). The reading in this example would be infinity, indicating the break is between points 3 and 4.

NOTE: Breaks are normally found at cracks or expansion joints.

7. Continue to check the resistance at points half way between the previous points (points 5 and 6 of Figure 4) until the break must be in a relatively short section of the guide wire. Refer to Guide Wire Repair to repair the guide wire.

2200 YRM 1229

Troubleshooting

NOTE: THE CIRCLED NUMBERS INDICATE POINTS THAT ARE BEING CHECKED IN THE GUIDE WIRE TROUBLESHOOTING PROCEDURES. 1.

2.

3.

4.

5.

6.

7.

8.

WIRE DRIVER GUIDE WIRE TERMINAL STRIP GUIDE WIRE BATTERY COMMON (GROUND) RACKS CAULK AREA BREAK IN GUIDE WIRE OHMMETER

9.

10.

11.

12.

13.

14.

15.

NEEDLE OF TOOL RACK SUPPORT FLOOR STUD CAULKING INSULATION WIRE STRANDS OF GUIDE WIRE CONCRETE

Figure 4. Guide Wire Troubleshooting

GUIDE WIRE REPAIR

Open Circuit Repair

Use the procedures in Guide Wire Troubleshooting to find the point of the open or short circuit of the guide wire.

1. Remove the elastic caulking approximately 203 to 254 mm (8 to 10 in.) on each side of the point of the open circuit.

Short Circuit Repair

2. Cut 76.2 mm (3.0 in.) off each end of the wire.

1. Remove the elastic caulking approximately 203 to 254 mm (8 to 10 in.) on each side of the point of the short circuit.

3. Strip 38.1 mm (1.5 in.) of insulation off each end of the wire. Twist the wire strands together. See Figure 5.

2. Install insulation to repair the short circuit.

4. Use a 1/2 inch diameter carbide tipped impact masonry bit and rotary/hammer drill to drill a hole 63.5 mm (2.5 in.) deep at the center of the break in the slot. See Figure 6.

3. Put the guide wire back into the bottom of the slot and fill the slot with caulking.

9

Troubleshooting

2200 YRM 1229

1. ELASTIC CAULKING 2. CONCRETE 3. GUIDE WIRE

4. SLOT 5. HOLE Figure 5. Guide Wire Preparation

5. Put a 101.6 mm (4.0 in.) length of shrinkable tubing on each wire. See Figure 6.

8. Center the shrinkable tubing over each splice and use a heat gun to shrink the tubing in place.

6. Cut a 355.6 mm (14.0 in.) length of jumper wire and strip 38.1 mm (1.5 in.) of insulation from each end.

Twist the wire strands together.

9. Seal each splice using sealant.

NOTE: The splice MUST be soldered to provide the required conductance and corrosion resistance.

7. Connect the jumper wire and each end of the guide wire using the "Western Union" splice. Solder each splice using a 60% tin, 40% lead, non-activated rosin core solder.

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10. Make a loop in the jumper wire centered over the hole. See Figure 7.

11. Put the wire in the groove and push the loop in the hole so the wire lays flat in the bottom of the slot.

12. Fill the slot with elastic caulking (silastic silicone).

2200 YRM 1229

1.

2.

3.

4.

GUIDE WIRE SHRINKABLE TUBING WESTERN UNION SPLICE JUMPER WIRE

Troubleshooting

5. SLOT 6. HOLE 7. SEALED SPLICE Figure 6. Guide Wire Splicing

1. GUIDE WIRE 2. SEALED SPLICE 3. JUMPER WIRE

4. EXPANSION LOOP IN HOLE 5. ELASTIC CAULKING IN SLOT Figure 7. Guide Wire Expansion Loop

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System II Wire Guidance Specifications

2200 YRM 1229

System II Wire Guidance Specifications Installation Requirements

Specifications

Wire Driver Output 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 Maximum Deviation Change Maximum Deviation Between Any Two Points Maximum Deviations Per 3.05 m (10 ft) Floor Flatness Requirements - For Lift Heights to 6096 mm (240 in.)

±3.0 mm (±0.12 in.) per 3.05 m (10 ft) 1.6 mm (0.062 in.) per 1.53 m (5 ft) 0.32 mm (0.0125 in.) per 305 mm (1 ft) One Deviation.

F65

In Direction of Vehicle Travel * Maximum Elevation Difference Maximum Elevation Change Rate

4.3 mm (1/6 or 0.17 in.) per 1829 mm (72 in.) * 3.6 mm (1/7 or 0.14 in.) per 305 mm (1 ft) *

At 90 to Direction of Vehicle Travel * Maximum Elevation Difference Maximum Elevation Change Rate

3.6 mm (1/7 or 0.14 in.) per 1372 mm (54 in.) * 3.6 mm (1/7 or 0.14 in.) per 305 mm (1 ft) *

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 Maximum Elevation Change Rate

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

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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) *

2200 YRM 1229

Installation Requirements

System II Wire Guidance Specifications

Specifications

Floor Magnetic Condition Requirements Floor Topping Wire Mesh or Rebar Other Magnetic Materials - Pipes, Rails, Drains Other Guide Wires With the Same or Different Frequencies

All iron or floor steel topping must be evenly distributed within 610 mm (24 in.) on both sides of the guide wire.

Wire mesh and rebar must be at least 102 mm (4 in.) below the guide wire.

Materials must be at least 152 mm (4 in.) below or 610 mm (24 in.) to the side of the guide wire.

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

Lift Truck Speed With Guide Path Deviation Zero Deviation (Load End First Only) 32 mm (1.25 in.) Deviation 38 mm (1.50 in.) Deviation (R30E only) 44 mm (1.75 in.) Deviation

8.8 km/h (5.5 mph) (R30EA only) 6 km/h (4 mph) maximum (R30E) 3.6 km/h (2.25 mph) maximum (R30EA) 3.6 km/h (2.25 mph) maximum 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).

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NOTES ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________ ____________________________________________________________

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Yale Materials Handling Corp.

1400 Sullivan Dr., Greenville, NC 27834-2011

2200 YRM 1229

6/08 (4/06)(9/05) Printed in U.S.A.