aonnist \wivw.hypassontine.comibiservceliwservice/27057 13H2_quick set up, 3.0 WIRE GUIDANCE SYSTEM SET UP (COMPLETE PROCEDURE). clJo|fo TPIETP (LO) ZAPTACSZPHOA 13:14:15 TPs_o. TPAD, TPAL_O. TPTE TPTP TPSL_O, 9 10 nia pao olfo ole TP3__o TP2_o. TPiL_9 RIBBON) [RIBBON CABLE | |CABLE ‘mE Gum ance ca TM14 = TMIS m™2 [Bl rca ji, ee [rae im TMs © Bs iM aston can> TMs E TM7(_alls| TMS fal oO oO 1 comsiton ds a3 £8 68 Fig. C. View of Wire Guidance Card Adjustment Pot locations REFER TO FIGURE B FOR TEST POINTS AND FIGURE C FOR TRIMMER POTS WHILE ADJUSTING THE WIRE GUIDANCE SYSTEM 1) Setting TM13, 14 and 15 on a brand new guidance card prior to installation into the ECM using an ohm meter. There are two ways to set up trimmer pots TM13, 14 and 15 on a brand new guidance card before itis installed into a ECM unit. Method #1: Mechanical setup Set the trimmer pots to a predefined number hypassontine.comtbiservceltwsorvica!2795713IH2_quick sat upletb.nimit mnaon ‘www hypassontine.comibsserviceltwserice/27957 181H2_quick set ups, oS) ie Prete] TMs THIS =o Method #2: Ohm meter setup There are four extra test points on the guidance card that are not defined in the service manual (TP16, 17, 18, 19), These test points require the use of a clip on type adapter on your Ohm meter leads. ‘Fert Prints TE16, 1718.19 [14 See Figure] foreloasup ducted beat br Zap Godan Read was hypassonine.comtbiservceltwsorvco!279571SIH2_quick sat upletb.nimiaonwit www hypassontine.comibsservceltwserice/27957131H2_quick set up Dyers Ue) Bt et, Referring back to the previous figures (1,2), we can use an ohm meter connected in a certain way to set up trimmer pots TM13, 14 and 15. Refer to Figure 3 below for ohm meter connections. hypassontine.comtbiservceltwsorvca!2795713IH2_quick sat upletb.himi smaonnist \wivw.hypassontine.comibiservceliwservice/27057 13H2_quick set up, oO oO Ohm Meter 0 asks vmx eupastcr can BEe2 mms w THIZ7 fl [al nica TMI3 TMI4 i] DIODE ovation i for THIS TesTPONTCARD TMT cal AMS oo TEL! [eee das $85 Figure 3 Hook up points for Ohm Meter M13 adjustment - Hook up ohm meter as shown in figure 3 (negative lead to TP16, positive lead to diode) and adjust TM13 to 15.5Kohms TM14 adjustment ~ Hook up chm meter as shown in figure 3 (negative lead to TP17, positive lead to TP18) and adjust TM14 to 56Kohms TMS adjustment ~ Hook up ohm meter as shown in figure 3 (negative lead to TP15, positive lead to TP19) and adjust TM15 to 20Kohms Caution: Make these adjustments with the card out of the ECM 2) Install the guidance card on the mother board (ECM) and make sure that all the connectors are in the correct position, 3) Switch on the power supply (Emergency switch ON, key switch ON, Side Gateds closed). 4) Check For Power To Guide Wire (guidance switch does not need to be on) a) Check that LED's on steering controller (DL1 and DL2) are on with unit over the wire or b) Drive unit near wire (in manual mode) and unit will slow iF both antennas are close to the wire hypassontine.com/tbiservceltwsorvica!2795713IH2_quick sat upletb.himi antaonnist RIEROM} RIeRoH caBle| CASLE — TMs = TMI o Tus. cn a [rm 92 " Emel ‘al | 5) Find Center Of Truck a) Locate the center of the MDU end of truck and install a pointer b) Locate the center of th vee ma [rao a fm LL \wvw.hypassontine.comibiserviceliwservice/2705713H2_quick set pict, e load wheel end of truck and install a pointer | SUPPORT PLASTIC SNAP TE (POINTER)TO SHOW THE (CENTEROF THE ANTENNAS FDCWWITH TAPE) 6) Set Plugging Detect Threshold (Section 9.0.A of steering section of service manual) a) Connect volt meter to TP2 (+) and TP15 (-) b) Check for +5 VDC at TP2 with truck stopped ©) Operate traction in MDU direction: 4) Adjust Trimpot TM12 for 0 VDC after contactor picks up, but before truck begins to move IRICDON| |RICBON caste | [caste amen Tut TMs cu ell "Tet ous OE fa LH a [jm ¢ 1 | cenmoum ke vs 4 marcald swe a |o o TU cvsaaen | ima = an sw on 7) Centering truck on the wire. Put the truck on the wire (far from the line driver generator). hypassonine, com/bisersceltwsorvea/279571SIM2_quick sat upletb.nimit sitaonnist ‘ww.hypassontine.comibiservcefiwservice/27057 13/H2_quick set upictb, VERY IMPORTANT: the traction and load wheel aerials have to be perfectly centered on the wire (consider pointer in point 5 as center). 8) Balance MDU Sensor Coils (NOTE: Coil voltages must be equal) (Section 9.0.8 of steering section of service manual) a) Move truck to position center of MDU end pointer over wire and load end pointer close to wire. b) Connect voltmeter to TP9(+) and TPL5(-) ) Adjust TM1 to 180 mv RMS AC 4) Connect voltmeter to TP10(+) and TP15(-) e) Adjust TM2 to 180mV RMS AC 9) Balance Load End Sensor Coils (Note: Coil voltages must be equal) (Section 9.0.6 of steering section of service manual) Check that load wheel sensor pointer is centered over wire. a) Connect voltmeter to TPL1(+) and TP15(-) b) Adjust TM3 to 180 mV RMS AC ¢) Connect voltmeter to TP12(+) and TP1S(-) 4) Adjust TM4 to 180 mV RMS AC Deane fo LL ee ® @C Le 10) MDU (Feedback) Pot Offset Adjustment (Section 9.0.€ of steering section of service manual) a) Insure steer wheel is straight (To do this travel down the wire in MDU direction 10 meters in guidance and coast to a stop - Truck may be parallel to wire at this point as illustrated In figure D on next page) b) Connect Handset ) Config Menu ~ Set Options ~ Special Pot Adj. > Set parameter ON (Enter) (This disables the steering system during adjustment. Don’t worry about the buzzer alarm enabled) 4) Connect volt meter to TP6 and TP15 e) Adjust TM10 as close to 0 VAC as possible f) When finished set Special Pot Adj back to “off” (switch the key off to stop the buzzer) hypassontine.comtbiservceltwsorvica!2795713IH2_quick sat upletb.nimit antaonnist ‘wiv hypassontine.comibiservceliwservice/2705713H2_quick set up a pa, ae AL o cle Figure D Dotted Line illustrates centerline of truck. Truck is travelling parallel to the wire 11) Steering Error Offset (Zero Reference for Steer Angle Shutdown Points) (Section 9.0.0 of steering section of service manual) a) Align MDU end over wire in guidance mode b) Travel in MDU direction and coast to a stop (After 30 seconds the system will go into "Time Out” ©) Connect volt meter to TP4(+) and TP15(-) 4d) Adjust TM9 for 0 VOC ) Drive unit along wire in MDU end and recheck voltage. (be sure to disconnect meter leads, otherwise truck will interpret the meter as an offset) traction wheel (MDU) direction only 12) Test wire guidance system with truck traveling a) Truck travels parallel to wire as in Fig.D: to center the truck on the wire, adjust trimmer TM10. Start with 2 turns one way and test the truck, if the parallel travel is worse, it means you have turned the trimmer the wrong way, turn the trimmer 4 turns in the opposite direction and try the truck again. If this adjustment is not sufficient, proceed by turning the trimmer 1 turn at a time until the truck travels perfectly over the wire b) The truck makes corrections that are too wide or fast: go to point 13 13) Steer Correction Response Adjustment and Loop Gain Adjustment (Gection 9.0.€ of steering section of service manual) a) TML3 (setting described at point 1- To high of a setting will cause MDU oscillation - too low will cause hypassonine. comitbiserviceltwsorvica!279571SIH2_quick sat upletb.nimi mtaonnist \wivw.hypassontine.comibiservceliwservice/27057 13H2_quick set up, ‘acquisition proves) b) TLS (setting described at point 1 - Turning clockwise increases sensitivity to the guide wire) (Set TM13 and TM15 together to reduce wander and oscillation of steering) NOTE: to reduce oscillation, we suggest that only trimmer TM15 is used, adjustment to TM13 other than that suggested could lead to difficulty during signal acquisition. FIBBON| |RI33.0%4} arte | \caBLe ¥ WIRE ODANCE CARD Wrmig = TMS m™2 lal ial lal THIS mira [J Eft m " ° [Jn aoe TESTPCIST CARD a 4 TM7L_ole| THs oo l aa a4 BR ES Set up of the Wire Guidance system in MDU direction is now complete, the relative settings must not be touched any more ! 14) Test wire guidance system with truck traveling in load wheel direction only (Ratio pot adjustment). If the truck carries out the corrections precisely on the center of the wire, go to g), otherwise, if the truck travels parallel to the wire, carry out the complete procedure. a) Drive unit in load wheel direction at slow speed b) Check that load wheel sensor and MDU sensor stay within 6mm (.25") of wire. ©) If load end sensor does not stay within 6mm (.25”) of wire, drive truck in load wheel direction to point where sensor is greatest distance off of wire. ) Connect meter to TP15 and check voltage at TP11 and 7P12 on the mV RMS AC scale to see which test point has the lower voltage. e) Increase the higher voltage Smv and decrease the lower voltage Smv by adjusting the trimpot, (TM3 for TPAL or TM4 for P12), and drive the unit again. Repeat this procedure until the load end sensor stays within 6mm 25") of the wire, } Drive unit at a higher speed and check that truck does not wander or dither in load wheel direction. 9) Adjust TM14 to fine tune truck to wire hypassontine.comtbiservceltwsorvica!2795713IH2_quick sat upletb.nimiaonnist ‘ww hypassontine.comibiservceliwservice/2705713/H2_quick set pict, Dotted line represents center of Load wheel sensor This illustration demonstrates behavior of truck if Load Wheel sensor needs to have an offset adjustment made to it. (Section 9.0.1 of steering section of service manual) a) Move truck away from wire ) Drive truck in MDU direction at an angle approx. 30 degrees to wire ©) Adjust TMS to acquire the wire in the shortest distance WORE GUIDANCE CARD TMi4 = TMS ™2 & is TM11 (a) T™I3 [,[raia m 9 fT 0 Du DL2 TESTPODT CARD Tus TM 72] ™8 ial oO wo coMECTOR TMLL fe zl fo EVIL fe evi 2 16) Guidance Alarm Tolerance (Section 9.0.L of steering section of service manual) a) TMS is Factory Set ~ do not adjust! b) Main Menu > Parameter Change > Fwd Upp Err Ant Set to 5 ¢) Main Menu, Parameter Change, Fwd Low Err Ant Set to 5 4) Main Menu, Parameter Change, Rev Upp Err Ant Set to 5 e) Main Menu, Parameter Change, Rev Low Err Ant Set to 5 17) Setting Pot out of Range Alarm (Section 9.0.M of steering section of service manual) a) TM7 is Factory Set — do not adjust!! b) Main Menu ~ Parameter Change ~ Upper Error Pot Set to 0 c) Main Menu, Parameter Change, Lower Error Pot Set to 0 If the procedure has been carried out correctly and precisely, the wire guidance system will work correctly, otherwise, go to point 18. If even after having carried out the tests in point 18, the system continues to work incorrectly, repeat the whole procedure from point 1. 18) Guidance Fualuation hypassoniin.combiservceltwsorvca!279571SIH2_quick sat upletb.himiaonnitt ww hypassontine.comibiservceliwservice/27057 13/H2_quick set ue, a) Connect meter to TPS(+) and TP15(-), set for DC voltage b) Drive the truck both directions while on Guidance c) Voltage should be close to 2.5 volts +/-.1 volts d) If the voltage stays low or stays high, then TM9 or TM10 could be out of adjustment. e) Connect meter to 1P3(+) and TP15(-), set for DC voltage ) Voltage should stay close to 2.5 volts +/- 1 volts 4g) If the voltage stays low or high then a sensor may need adjustment or TM9 or TM10 may need adjusting fh) Ifthe voltage at TPS and TP3 stays close to 2.5 volts while traveling either direction in guidance, then the wire quidance setup is complete. RIBBON |RIBBON| ICABLE | |CABLE RE GUIDANCE CARD TMi4 TMS TM12 3 a] TML3 Twa LI [ruc mo 0 [,]rme ° DLI Dla TESTPOMT CARD TM7 alls! THB coMMECTOR lolol loll! diddd ge ae BS Of TPTPTE (LC) ZAPI ACSZPHOA 13:14 15 TPs TP7L_2. TP6__o TPT? TPTP TPS[_O aa pee TP4| 0 alfo allo TP3,_° TP2, 0 TP1 o Wire guidance setup is complete, the following pages give additional information about the Wiring Guidance system Additional information concernina Test Paints and Trimmer Pats. hypassoniine.com/biservceltwsorvea/2795713IH2_quick sat upletb.Nimi tonsaonnist :wvw-hypassontine.comibiservceltwservice/27057 13/H2_quick set pict, TP-5 - This testpoint will show you the Pot Wiper in Real Time. Ideally while the truck is guiding down the guidepath you want the voltage to stay roughly between 2.4 and 2.6 volts +/- .1 volt. This testpoint is what the microprocessor in the ECM uses to determine shut down alarm “POT OUT OF RANGE”. If the voltage at test point 5 stays either high (2.8 to 3.1 volts) or low (2.3 to 2 volts) the truck will be to sensitive to a shutdown alarm based on how the parameters for UPPER ERROR POT and LOWER ERROR POT are set. TM9/TM10 affect this voltage. ‘P-3 - This will show in real time the Antenna position over the wire. You should see 2.5 volts with a perfectly centered antenna. The closer the guidance system is set to keep this 2.5 volt signal at TP-3 the better the guidance system is running, Use this Test Point and TP-5 to determine Guidance performance. This test point is what the ECM uses to determine when the LATERAL OUT alarm will occur depending on how the parameters FWD UPP ERR ANT, FWD LOW ERR ANT, REV UPP ERR ANT, REV LOW ERR ANT are set. If the voltage stays to high (2.7 to 3 volts) or to low (2.3 to 2 volts) the truck will be sensitive to a shutdown alarm. M9 and TM10 both can cause the truck to guide parallel to the guidewire. TM10 will show up going MDU direction while TM9 can cause the truck to guide parallel to the guidewire both directions. So it is easy to confuse which trimmer is out of adjustment. TP-5 can assist in this determination, TM13 (amount of steer correction) and TM45 (sensitivity to a guidance error) - These two trimmer pots are extremely difficult to set. Improper setting could cause the truck to go sideways in an aisle when coming off the wire, As a starting point be sure TM43 is set to 6 and TM15 is set to 9 Test Point Definitions TP ~ MDU Guide Antenna Error (MVac) P2 - Plugging Signal (Svdc when traction at rest or braking, Ovde when traveling 1P3 ~ Antenna Error Conversion (relates to ANTENNA ERROR in the handset) VDC (the voltage at this test point is what the ECM uses to determine LATERAL OUT alarm) TP4 - Wire Guidance Error (test point to show when steer motor is active ~ Positive values for turning Clockwise, Negative values for turning Counter Clockwise) TPS - MDU pot Feedback (the voltage at this test point is what the ECM uses to determine POT OUT Of RANGE alarm) TP6 ~ Feedback Pot Wiper Voltage (Vac in wire guidance mode, Vdc in manual) TP7 - Fixed 1.767 Vac voltage when the MDU Guide Antenna is near the wire TPS - Fixed 1.767 Vac voltage when the LOAD WHEEL Guide Antenna is near the wire TP9 - MDU Guide Antenna Coil Signal (Vac) - set to 160MVac TP10 — MOU Guide Antenna Coil Signal (Vac) - set to 180MVac P11 — LOAD WHEEL Guide Antenna Coil Signal (Vac) - set to 180MVac P12 — LOAD WHEEL Guide Antenna Coil Signal (Vac) ~ set to 180MVac P13 — 12Vdc supply test P14 - Negative 12Vdc supply test P15 — Ground. hypassontine.comtbiservceltwsorvica!2795713IH2_quick sat upletb.nimit avi