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................................................................................................................................................................ 1
Description .......................................................................................................................................................... 1
Installation Procedure.......................................................................................................................................... 3
Checks and Adjustments..................................................................................................................................... 4
Checks ............................................................................................................................................................ 4
Adjustments ................................................................................................................................................... 6
Troubleshooting ................................................................................................................................................... 7
Wire Driver Troubleshooting ............................................................................................................................ 7
Guide Wire Troubleshooting ............................................................................................................................ 8
Guide Wire Repair........................................................................................................................................... 9
Short Circuit Repair .................................................................................................................................... 9
Open Circuit Repair .................................................................................................................................... 9
System II Wire Guidance Specifications.............................................................................................................. 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
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.
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 us-
ing 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 fre-
quency is 6250 ±10 Hz and is factory set. Another com-
mon 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 op-
erate the unit for approximately four hours. The wire
driver is normally operated on the AC power continu-
ously, even when a guide signal is not needed. This
prevents the automatic battery operation from discharg-
ing the batteries. It also keeps the charging circuit op-
erating so the batteries have a full charge.
Description
Refer to the section Guide Wire Installation 2200 YRM
1230 for information on the guide wire installation.
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 indi-
cates that the unit is operating on the backup batter-
ies.
• Rechargeable batteries - Provide backup power.
• Power circuit board - The power board provides the
correct voltages to the logic board and keeps the bat-
teries 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. DOOR 14. FUSE 2 (1 AMP, POWER BOARD)
2. FAULT LAMP 15. LED 2 (POWER BOARD)
3. INTERLOCK SWITCH 16. DC POWER SWITCH S1
4. AC OUTLET 17. LED 3 (POWER BOARD)
5. TERMINAL STRIP 18. FUSE 3 (1 AMP, POWER BOARD)
6. FREQUENCY SELECT SWITCHES 19. GUIDE WIRE CONDUIT
7. CASE 20. BATTERIES
8. LOGIC BOARD 21. POWER SOURCE CONDUIT
9. LED 1 (LOGIC BOARD) 22. LED 1 (POWER BOARD)
10. FUSE 1 (1 AMP, LOGIC BOARD) 23. 115/230 VOLT AC SELECT SWITCH S2
11. GUIDE WIRE TERMINAL STRIP 24. FUSE 1 (1 AMP, POWER BOARD)
12. CAPACITOR C31 25. SPECIFICATION LABEL
13. POWER BOARD

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. In-
stall 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 A. SHOWN SET FOR 6.25 KHZ
OFF before installing the wire driver. B. SHOWN SET FOR 5.2 KHZ

3. Install the wire driver so the bottom of the box is Figure 2. Frequency Select Switches
approximately 1.5 m (5.0 ft) from the floor and is
5. To set the wire driver for a frequency of 6.25 KHz,
in an area that is reasonably protected. The fault
locate the frequency select switches (on the logic
lamp must also be visible during normal operations.
board to the right of the interlock switch near the
The door hinge is on the left side. Flanges at the
hinge) and proceed as follows:
top and bottom of the case have holes for nails or
screws. The conduit for the AC power source in- a. Multiply the frequency (in KHz) by 20.
stalls at the left hole in the bottom of the case. Make 6.25 × 20 = 125
sure that the 115/230 switch is set to 115 for a 115
volt AC power source and 230 for a 230 volt AC b. Subtract 2.
power source. Connect the AC L1 to the top ter- 125 2 = 123
minal of the AC terminal strip. Connect the neu-
tral/ground to the grounding screw on the side wall c. Determine if the first (left most) switch value
of the case. Connect the L2 to the bottom terminal. (128) is greater than the calculated value of
Step b (123 for this frequency). If so, set the
4. The frequency select switches (8 switch set) on the switch to 0 (down). If not, set the switch to 128
logic board sets the frequency of the wire driver. (up).
The switch sets in Figure 2 are shown set for fre-
quencies of 6.25 and 5.2 KHz. The eight switches If the switch value is NOT greater than the cal-
each have a specific value as shown in Figure 2. culated value, subtract the switch value from
The switch to the far left has a value 128 (up). The the calculated value and continue to the next
next switch to the right has the value of 64 (up). If step.
the switch is in the OFF (down) position, it has no
If the calculated value of Step b was 130, this
(0) value.
remaining value would be 2 (130 128 = 2).
For this frequency, the switch value is NOT
WARNING greater, so the switch is set to 0. Since we have
Make sure the AC power source is set to OFF at not subtracted a switch value from the calcu-
the source (circuit breaker) before setting the fre- lated value, the remainder is still the calculated
quency select switches. value (123).

3
Checks and Adjustments
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.
e. Next switch value (32) is NOT greater than the
remaining value (59). Set switch to 32 (up) then
subtract.
59 32 = 27
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.
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 volt-
age 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
2200 YRM 1229
h. Next switch value (4) IS greater than the re-
maining value. Set switch to 0 (down) and con-
tinue.
i. Next switch value (2) is NOT greater than the
remaining value (still 3). Set switch to 2 (up)
and subtract.
3 2=1
j. Next switch value (1) is NOT greater than the
remaining value (1). Set switch to 1 (up).
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.
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 Troubleshoot-
ing section.
2200 YRM 1229 Checks and Adjustments

1. FAULT LAMP (LED 2 LOGIC BOARD) 13. CAPACITOR C31

2. INTERLOCK BUTTON 14. TP3
3. FREQUENCY SELECT SWITCHES 15. TP4
4. LOGIC BOARD 16. TOGGLE SWITCH S1
5. R89 CALIBRATION ADJUST 17. CP2
6. TP2 18. + DC (PIN 1)
7. R47 CURRENT ADJUST 19. COMMON (PIN 2)
8. R78 OUTPUT AMPLITUDE ADJUST 20. DC (PIN 3)
9. TP1 21. AC (PIN 4)
10. R62 CURRENT WINDOW ADJUST 22. 15 OHM, 10 WATT RESISTOR (LOAD)
11. LED 1 23. OSCILLOSCOPE
12. TERMINAL STRIP TS1 24. 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/ohmme-
ter 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 prop-
erly set or follow the setup procedure in the Instal-
lation Procedure.
2. Disconnect both ends of the guide wire from the ter-
minal 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 read-
ing 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 counterclock-
wise. Pull the interlock switch to set the AC power
ON.
5. Adjust R78 (output amplitude) fully clockwise. Ad-
just 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 clock-
wise.
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 Possible Cause

Step 2 in the section Checks Verify that the AC supply is correct and the power board line switch S2 is
is not correct. 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 If the output current level is not adjustable, check that all connections are
correctly. 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 proce-
dure has the steps necessary to find an open circuit.
WARNING
Make sure that there are no trucks operating on any
part of the guide wire before troubleshooting or re-
pairing the guide wire. Personal injury or equip-
ment 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
8
2200 YRM 1229
slot. If the guide wire installation drawing is avail-
able, locating the "caulk" areas will be easier. An
area for each "half" of the loop, as close as possi-
ble 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 resis-
tance 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 nor-
mally 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).
CAUTION
Fill each "needle" hole with caulking after the "nee-
dle" 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 expan-
sion joints.
7. Continue to check the resistance at points half way
between the previous points (points 5 and 6 of Fig-
ure 4) until the break must be in a relatively short
section of the guide wire. Refer to Guide Wire Re-
pair to repair the guide wire.
2200 YRM 1229 Troubleshooting

NOTE: THE CIRCLED NUMBERS INDICATE POINTS THAT ARE BEING CHECKED IN THE GUIDE WIRE TROU-
BLESHOOTING PROCEDURES.
1. WIRE DRIVER 9. NEEDLE OF TOOL
2. GUIDE WIRE TERMINAL STRIP 10. RACK SUPPORT
3. GUIDE WIRE 11. FLOOR STUD
4. BATTERY COMMON (GROUND) 12. CAULKING
5. RACKS 13. INSULATION
6. CAULK AREA 14. WIRE STRANDS OF GUIDE WIRE
7. BREAK IN GUIDE WIRE 15. CONCRETE
8. OHMMETER

Figure 4. Guide Wire Troubleshooting

GUIDE WIRE REPAIR Open Circuit Repair

Use the procedures in Guide Wire Troubleshooting to 1. Remove the elastic caulking approximately 203 to
find the point of the open or short circuit of the guide 254 mm (8 to 10 in.) on each side of the point of
wire. 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 3. Strip 38.1 mm (1.5 in.) of insulation off each end
254 mm (8 to 10 in.) on each side of the point of of the wire. Twist the wire strands together. See
the short circuit. 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
3. Put the guide wire back into the bottom of the slot 63.5 mm (2.5 in.) deep at the center of the break
and fill the slot with caulking. in the slot. See Figure 6.

9
Troubleshooting 2200 YRM 1229

1. ELASTIC CAULKING 4. SLOT

2. CONCRETE 5. HOLE
3. GUIDE WIRE

Figure 5. Guide Wire Preparation

5. Put a 101.6 mm (4.0 in.) length of shrinkable tubing 8. Center the shrinkable tubing over each splice and
on each wire. See Figure 6. use a heat gun to shrink the tubing in place.

6. Cut a 355.6 mm (14.0 in.) length of jumper wire and 9. Seal each splice using sealant.
strip 38.1 mm (1.5 in.) of insulation from each end.
Twist the wire strands together. 10. Make a loop in the jumper wire centered over the
hole. See Figure 7.
NOTE: The splice MUST be soldered to provide the re-
quired conductance and corrosion resistance. 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.
7. Connect the jumper wire and each end of the guide
wire using the "Western Union" splice. Solder each 12. Fill the slot with elastic caulking (silastic silicone).
splice using a 60% tin, 40% lead, non-activated
rosin core solder.

10
2200 YRM 1229 Troubleshooting

1. GUIDE WIRE 5. SLOT

2. SHRINKABLE TUBING 6. HOLE
3. WESTERN UNION SPLICE 7. SEALED SPLICE
4. JUMPER WIRE

Figure 6. Guide Wire Splicing

1. GUIDE WIRE 4. EXPANSION LOOP IN HOLE

2. SEALED SPLICE 5. ELASTIC CAULKING IN SLOT
3. JUMPER WIRE

Figure 7. Guide Wire Expansion Loop

11
System II Wire Guidance Specifications
System II Wire Guidance Specifications
Installation Requirements
Wire Driver Output Requirements
Standard
Frequency
Current
Optional
Frequency
Current
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.)
In Direction of Vehicle Travel *
Maximum Elevation Difference
Maximum Elevation Change Rate
At 90 to Direction of Vehicle Travel *
Maximum Elevation Difference
Maximum Elevation Change Rate
In Any Other Direction of Vehicle Travel *
Maximum Elevation Difference
Maximum Elevation Change Rate
Floor Flatness Requirements - For Lift Heights
Above 6096 mm (240 in.)
In Direction of Vehicle Travel *
Maximum Elevation Difference
Maximum Elevation Change Rate
At 90 to Direction of Vehicle Travel *
Maximum Elevation Difference
Maximum Elevation Change Rate
In Any Other Direction of Vehicle Travel *
Maximum Elevation Difference
Maximum Elevation Change Rate
12
2200 YRM 1229
Specifications
6520 ±10 Hertz
76 to 80 mA
5200 ±8 Hertz
34 to 36 mA
±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
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) *
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) *
1.8 mm (1/14 or 0.07 in.) per 305 mm (1 ft) *
1.8 mm (1/14 or 0.07 in.) per 305 mm (1 ft) *
F95
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) *
2.5 mm (1/10 or 0.10 in.) per 305 mm (1 ft) *
2.1 mm (1/12 or 0.08 in.) per 305 mm (1 ft) *
1.1 mm (1/24 or 0.04 in.) per 305 mm (1 ft) *
1.1 mm (1/24 or 0.04 in.) per 305 mm (1 ft) *
2200 YRM 1229 System II Wire Guidance Specifications

Installation Requirements Specifications

Floor Magnetic Condition Requirements
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
610 mm (24 in.) to the side of the guide wire.
Other Guide Wires With the Same or Different Fre- Must be at least 762 mm (30 in.) away from
quencies the guide wire and guide path.
Lift Truck Speed 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 in.) Deviation (R30E only) 3.6 km/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).

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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.