Maintenance

GUIDE WIRE
INSTALLATION
MTC10, MTC13 (NTA030SA) [A868, A872];
MTC15 (NTA040SA) [A869, A873];
MTC18 (NTA040DA) [A870, A874];
MTC13 (NTA030SB) [B868];
MTC15 (NTA035SB) [B869]; SS030BF [A474];
FS030BF [A497]; OSO30EA [A801]; OSO30EB [B801];
OSO30EC [C801]; OS/SS030BC [B826];
OS/SS030BD [C826]; OS030EF [D801];
OS/SS030BE [D826]; OS030BF [E826]

PART NO. 520371764 2200 YRM 1230

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened, and
that the load being lifted is balanced. Make sure the crane, cables, and chains have the capacity to
support the weight of the load.

• Do not lift heavy parts by hand, use a lifting mechanism.

• Wear safety glasses.

• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on electric lift
trucks. Disconnect the battery ground cable on internal combustion lift trucks.

• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE LIFT
TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.

• Keep the unit clean and the working area clean and orderly.

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

• Always use YALE APPROVED parts when making repairs. Replacement parts must meet or exceed
the specifications of the original equipment manufacturer.

• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using force to
remove parts.

• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or if the unit
needs repairs.

• Be sure to follow the WARNING and CAUTION notes in the instructions.

• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels and when
working on these fuel systems.

• Batteries generate flammable gas when they are being charged. Keep fire and sparks away from the
area. Make sure the area is well ventilated.

NOTE: The following symbols and words indicate safety information in this manual:

WARNING
Indicates a hazardous situation which, if not avoided, could result in death or
serious injury.

CAUTION
Indicates a hazardous situation which, if not avoided, could result in minor
or moderate injury and property damage.

On the lift truck, the WARNING symbol and word are on orange background.
The CAUTION symbol and word are on yellow background.
Guide Wire Installation Table of Contents

TABLE OF CONTENTS

General................................................................................................................................................................ 1
Description .......................................................................................................................................................... 1
Guide Wire Physical Installation .......................................................................................................................... 2
Equipment ........................................................................................................................................................... 10
Specifications ...................................................................................................................................................... 13
Wire Slot and Expansion Loop Specifications................................................................................................. 13
Material and General Specifications ............................................................................................................... 14
System II Wire Guidance Specifications.............................................................................................................. 17
Pre-Installation Information Form ........................................................................................................................ 18

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];
SS030BF [A474];
FS030BF [A497];
OSO30EA [A801];
OSO30EB [B801];
OSO30EC [C801];
OS/SS030BC [B826];
OS/SS030BD [C826];
OS030EF [D801];
OS/SS030BE [D826];
OS030BF [E826]

©2012 Yale Materials Handling Corp. i

2200 YRM 1230
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
Description
There are several things that must be done before be-
ginning the actual installation of the guide wire. Careful
planning can prevent costly and time consuming mis-
takes. It may be easier and cheaper for the wire in-
staller to repair any minor floor irregularities in the truck
path during guide wire installation. It is best the racks
can be installed and approved by the customer and Yale
Company before the installation of the guide wire. If the
racks cannot be installed before the guide wire instal-
lation, rack location must be referenced to one or more
permanent benchmark points. These points must be
established and agreed upon by the customer and Yale
Company. All dimensions for the guide wire installation
must be referenced to the approved racks or the bench-
marks. When the guide wire path is known, a physical
inspection of the floor must be done by the customer
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 cus-
tomer, the dealer, or Yale Company. The purpose of this
wire and rack installation drawing is to plan the contin-
uous wire path of up to 1524 m (5000 ft) per line driver.
The drawing will also be used to show:
1. Dimensions for wire routing.
2. Walls and traffic aisles.
3. Location of wire driver in a visible area.
4. Total estimated wire length.
5. Total saw cut length.
6. Location and type of floor discontinuities.
7. Location of desired expansion loops.
Description
wire installation therefore requires a review and com-
plete 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.
8. Location and capacity of electrical outlets.
9. The location and type of connectors necessary to
connect a garden hose to the cold water source(s).
If possible, the drawing should include a 12.2 m (40 ft)
straight section of guide wire outside the rack aisle for
truck testing and alignment. All dimensions must be ref-
erenced to the approved racks or to the agreed on per-
manent benchmark points and be given in inches or feet
and inches. The drawing must be mutually approved by
the customer and Yale Company.
At least two weeks before the date of installation of the
wire, a pre-installation information form must be com-
pleted by the dealer. At this time, the working hours
will be tentatively scheduled with the customer and the
amount of customer help (if any) will be determined. If
possible, establish cutting hours when customer per-
sonnel and vehicle traffic through the cutting area are
at a minimum. Alternate traffic patterns must be devel-
oped to avoid congestion during installation. See Fig-
ure 2.
The amount of normal traffic through the work area, the
number of people close enough to the saw cutting to
require ear protection, protection of electrical and wa-
ter lines from vehicle traffic, and venting for the exhaust
if a gasoline powered saw is used, are things to be con-
sidered in establishing the working hours. Establish ar-
eas for breaks and lunch for the work party. If neces-
sary, define any off-limit areas and determine security
arrangements for entering and exiting the work site, es-
pecially during odd hours.
At this time, the movement or protection of any material
or equipment in the work area must be agreed to by
the customer. Determine from the customer a suitable
dump site for the slurry from the cutting operation.
Make sure container handling and transportation will be
available for handling the slurry from the installation site
to the dump site. Make sure the floor is smooth enough
1
Guide Wire Physical Installation 2200 YRM 1230

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
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
Figure 1. Wet Vacuum
electrical and building codes. If necessary, the control
module can be removed and stored in a safe place until
all work is completed.

Guide Wire Physical Installation

1. Make sure the work party knows the security ar-
rangements for access to work site. Show them the
location of restrooms and the break and lunch ar-
eas. Make sure they know the location of all off-limit
areas.
2. Locate the power and cold water sources. Provide
protection for the power and water lines if vehicles
will cross lines. Install the pedestrian and other traf-
fic barricades. See Figure 2. Distribute ear pro-
tection devices to customer personnel and cutting
crew. Make sure all material or equipment has been
removed from the area or is protected from the dust
and water of the cutting process.
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.

3. Locate the benchmark from which all dimensions

are taken. In the example of Figure 3, the bench-
mark is the column which is flush with the rack face.
If the racks are already installed and have been
checked and approved, measurements can be
taken from the racks. Otherwise, measurements
must be taken from the permanent benchmark
points. Any variation between the actual ware-
house, racks, or guide wire path and the drawing
MUST be resolved BEFORE continuing the layout
and cutting. Wire guided tracks operate in mini-
mum clearance conditions so all changes must be
approved before installation continues.
Figure 2. Traffic Barricades

2
2200 YRM 1230
Figure 3. Benchmark
7. The entire chalk path must be spray coated us-
8. Mark any floor irregularities which require expan-
Figure 4. Marking Guide Wire Path
6. The chalk line must be exactly located over the pre-
viously marked points. See Figure 5. Slight varia-
tions are not allowed due to the critical nature of
wire straightness. The line must be snapped so the
red chalk is highly visible along a continuous path
with no breaks.
Guide Wire Physical Installation
Figure 5. "Snapping" Chalk Line
ing the specified clear sealer to prevent its being
erased prior to or during cutting of the slot. See
Figure 6.
Figure 6. Spraying Chalk Line
sion loops or which must have the slot filled with
silicon elastic instead of grout to allow for expan-
sion. Metal within 50.8 mm (2 in.) of the saw cut
must be removed and the area filled with epoxy and
ground flush with the surface. In Figure 7, the two
metal studs are small enough that they were left in
the floor and ground flush with the concrete surface.
The cracks and expansion joint shown were reme-
died by filling the slot with caulking for 101.6 mm
(4 in.) on each side of the discontinuity.
3
Guide Wire Physical Installation 2200 YRM 1230

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 tol-
erance is not within the specification on the instal-
lation drawing.

Figure 8. Low Spot Filled

10. On a new or unstable floor, expansion loops must

be made at each expansion joint between concrete
pads and at the end of each aisle. Minor cracks,
where the concrete cannot shift, do not need ex-
pansion loops. However, the guide wire must be
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 Specifica-
tions section. The areas that have caulking make
the guide wire continuity checking and repairs much
easier.

11. Saw alignment is the most critical step in cutting the

floor. The first cut must be made in a main or cross
aisle where the truck will not need to guide on the
wire. Before turning the saw on, it should be pushed
forward and backward along a 6.1 m (20 ft) length,
and the steering adjusted until it tracks along that
length without deviation. This must be done at the
beginning of each cut. See Figure 9.

Figure 7. Floor Irregularities

4
2200 YRM 1230
Figure 9. Aligning Saw
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
Guide Wire Physical Installation
adjustment can be noted for later reference. The
speed and flow can also very for different areas or
floor composition. The depth of cut (slot depth) will
also decrease with a speed increase or an increase
in concrete hardness or density.
13. The depth of the slot must be 11.18 mm (7/16
or 0.44 in.) for one wire and 12.70 mm (1/2 or
0.50 in.) for two wires. A standard 3.175 mm (1/8
or 0.125 in.) blade is acceptable. If three or four
wires are planned, the slot must be deep enough
to ensure 6.35 mm (1/4 or 0.25 in.) grout over
the top wire. A diamond blade will hold the slot
depth with only infrequent adjustments for wear.
Measure the depth continually and adjust the saw
as necessary to maintain a depth tolerance of
±1.5875 mm (±1/16 or 0.0625 in.). A gradual tran-
sition is acceptable if the top wire will be covered
with the minimum 6.35 mm (1/4 or 0.25 in.) grout.
The transition must be over a distance of more
than 1.5 m (5 ft).
14. While sawing, constant attention must be on the
saw path. See Figure 10. Every effort must be
made to keep the indicators and blade in-line. Make
sure the slot is within tolerances shown in the Spec-
ifications section. The end of each cut must extend
at least 203.2 mm (8 in.) beyond the actual inter-
section point.
Figure 10. Keep Saw on Path
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.
5
Guide Wire Physical Installation 2200 YRM 1230

20. Just prior to laying the wire, the slot must be cleared
using an ice pick or similar instrument. Then vac-
uum the slot and surrounding area, to make sure
there are no granules left in the slot. See Figure 13.

Figure 11. Vacuum Slurry Immediately Figure 12. Electric Hand Saw

16. Saw alignment is critical at all times. If the chalk

line is difficult to see, a flashlight can be used. See
Figure 10.

WARNING
If water is used with the electric hand saw, the saw
MUST have an insulated case and care must be
taken to prevent electrical shock.

17. For short distances, to widen the slot for expan-

sion loops, and to deepen the slot when needed,
an electric hand saw can be used. See Figure 12.
Although this can be a dry cut, a water supply for
cooling and lubrication is better. A water type fire
extinguisher filled with water can be used.

18. No special care is given to the slot after cutting. It

can be left overnight without covering it. If left for
long periods, duct tape can be used to keep the slot
free of dirt.
21. The wire is installed in the slot directly from the reel.
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 13. Vacuum Slot
A blunt instrument is used to press the wire into
the bottom of the slot. The instrument shown in
Figure 14 is a keyhole saw with the blade ground
smooth. If necessary, use pieces of cork or card-
board to keep the wire in the bottom of the saw cut.
It is important for correct guidance that the wire is
kept at the bottom of the saw cut. The cork or card-
board must be a tight fit in the slot to hold the wire
at the bottom of the slot.

6
2200 YRM 1230 Guide Wire Physical Installation

Figure 14. Installing the Wire

22. Whenever the wire passes around the corner, it

must be taped to prevent chafing. An alternative
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.

Figure 15. Loop at Corner

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 16. Splice

7
Guide Wire Physical Installation 2200 YRM 1230

Legend for Figure 16

1. SHRINKABLE TUBING
2. WESTERN UNION SPLICE
3. SEALANT
4. SOLDERING IRON
5. SOLDER
6. HEAT GUN

24. Solder the wires together and center the shrinkable

tubing over the splice. Use the heat gun or hold the
soldering iron under the splice to shrink the tubing
around the splice until it is tight. Coat the splice
with the specified sealant. If needed, chisel or saw
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 con-
venience. If the wire driver is located in a traffic
area, the conduit must be buried. A 50.8 × 50.8 ×
50.8 mm (2 × 2 × 2 in.) hole for the conduit can be
made by drilling, sawing, and chiseling. If located
in a non-traffic area, the guide wire can exit the con-
duit and enter the slot at the floor surface. However,
the end of the conduit and slot must be covered with
grout as shown in Figure 17.

26. The next step is to test the continuity of the wire.

See Figure 18. This must be done before grout-
ing because corrections are difficult to make after
the grout is installed. A voltage/ohmmeter (VOM) Figure 17. End of Conduit Covered
connected to the wire ends will indicate four to five
ohms per 304.8 m (1000 ft) of wire, if the wire has
continuity. An infinity indicates a break in the wire.
A reading of much less than the proper resistance
indicates a short circuit between sections of the
wire. Inspect the total length of the wire to locate
any break(s) or short(s) and make the necessary
repairs. The wire driver control module can be in-
stalled now or as the final step.

27. All cracks and breaks in the floor must have been
previously marked. The entire guide path must be
inspected. Fill the slot using elastic caulking for a
minimum of 50.8 mm (2 in.) each side at all expan-
sion loops, cracks, and over any splices. Fill the slot
flush with the surface. Generally, it is better to use
too much than too little caulking. This step must be
completed before grouting begins. See Figure 19.

Figure 18. Testing Wire

8
2200 YRM 1230 Guide Wire Physical Installation

Figure 19. Caulking Slot Figure 20. Grouting

28. Now the grout can be applied to the entire guide

path. With a resin-mixed grout, the consistency will
be stiff, so pouring is not possible. As shown in Fig-
ure 20, installing the grout with a trowel is required.
If water-mixed grout or thin epoxy is used, a pour-
ing technique is possible. Plastic ketchup or chalk
bottles can be filled and used to squirt the grout into
the slot, while a second person keeps the contain-
ers filled. Another possible technique is to insert
and tape a funnel to one end of a long tube, such
as a golf tube, and tape a small funnel or chalk bot-
tle top to the other end. See Figure 20. Then one
person can hold the small funnel to direct the grout
into the slot, while the second person pours grout
into the large funnel. If the grout begins to harden
and will not pour, dump the batch, clean the tools,
and make a new batch.

29. It is extremely important for the grout to be flushed

with the floor surface. Because the grout hardens
rapidly, only one segment of the guide path must
be grouted at one time. Before moving to the next
segment, the grout must be scraped with a trowel Figure 21. Smoothing Grout
or spatula and smoothed before it solidifies. See
30. As mentioned previously, the wire driver conduit to
Figure 21. The length and timing of each segment
the floor can be either a buried or surface interface.
will depend on the consistency of the grout. Have a
As shown in Figure 17, the wire driver is located
readily available water supply with 18.93 liter (5 gal)
where no pedestrian or equipment traffic will occur,
pails and other supplies to allow a more efficient
so the exposed wire and the end of the conduit is
process. The 208.2 liter (55 gal) drum for the wet-
simply covered with a few inches of grout.
dry vacuum can be partially filled with water to rinse
the equipment periodically.

9
Equipment 2200 YRM 1230

31. The entire floor must be cleaned and swept. See

Figure 22. The guide path will be almost unnotice-
able in the floor. The extent of the cleanup must
be mutually agreed to by the customer and the in-
staller. Generally, a water or mopping cleanup is
the customers responsibility.

32. Now the control module can be installed in its hous-

ing, and the wire continuity checked again. Con-
nect and check the wire driver according to Wire
Driver Manual 2200 YRM 1229.

33. Inspect the installation with the customer so that the

customer knows that the installation is satisfactorily
completed, and wire continuity has been checked.

Figure 22. Sweeping Guide Path

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 To ensure straight lines. Sufficient piano wire or string for the
beam 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.

10
2200 YRM 1230 Equipment

Table 1. Equipment (Continued)

2. Two (minimum) general purpose One cutting and a minimum of one replacement or spare.
355.6 mm (14 in.) diamond blades 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 For drilling vertical expansion loop holes.
3/4 inch bit capacity
6. 1/2 and 3/4 inch carbide tipped impact For rotary/hammer drill.
masonry bits
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.
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.

11
Equipment 2200 YRM 1230

Table 1. Equipment (Continued)

3. Pliers, wire strippers, solder, and solder For making wire splices.
gun or iron
4. Heat shrinkable tubing, electrical tape, Sufficient length of specified tubing to insulate and protect
and sealant 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. Specified grout For filling slot over wire. Sufficient quantity to finish job.
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 For getting grout mix into slot.
bottle tops and golf tube
8. Knee pads or kneeling pad Recommended for knee protection during grouting operation.
Testing Equipment
1. A volt/ohmmeter (VOM). For checking guide wire continuity and wire driver output.
Beckman HD 100 Recommended. Meter MUST have a reading resolution of 100 uV and an RMS
Fluke 8020A acceptable at 6.25 KHz or accuracy of ±5 percent at the frequency of the wire driver.
less

12
2200 YRM 1230 Specifications

Specifications
WIRE SLOT AND EXPANSION LOOP
SPECIFICATIONS
Figure 23 shows the wire slot and expansion loop spec-
ifications.

A. SLOT D. HORIZONTAL METHOD

B. EXPANSION LOOPS E. GROUT OR EPOXY
C. VERTICAL LOOP (PREFERRED METHOD) F. ELASTIC CAULKING
1. CONCRETE 5. CRACK
2. SLOT 6. EXPANSION JOINT BETWEEN CONCRETE
3. GUIDE WIRE PADS
4. 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

13
Specifications 2200 YRM 1230

MATERIAL AND GENERAL

SPECIFICATIONS
Table 2 shows the material specifications. Table 3
shows the general specifications.

Table 2. Material Specifications

Material Specification
1. Wire 6 AWG, stranded 19/29 copper type B, 0.010 PVC insulation, any color,
1.98.12 mm (5/64 or 0.078 in.) diameter
Suggested vendors:
Beldon 9980
Alpha 1858/19
Newark 27F3223WM or 37F571WM
2. Solder Tin 60%, lead 40%, non-activated rosin core, 16 gauge
Suggested vendors:
Kester
Ersin Multicore
Newark 33F228, 33F315, 33F217, 81N1591
Duratec TLR6016-1
3. Heat Shrinkable Tubing 3.175 mm (1/8 or 0.125 in.) diameter, any color, PVC, polyolefin or teflon
Suggested vendors:
Voltrex PVS-008, TTS-514, SST-008, FPS-008
Alpha FIT-221-1/8
Newark 37F6992, 81N2701, 37N1170
4. Sealant (Wire Splice) Provide splice corrosion protection from moisture, oil, or acid.
Suggested product (equivalent products acceptable):
Spray Tec "Crystal Clear Insulating Acrylic"
Type 32N291 (MIL-TT-0048)
Newark P/N 00Z245
3M "IVI-Spray" Electrical Sealer No. 2530

Suggested vendor:
Newark Electronics Chicago
Graybar
5. Caulking Must remain elastic and not shrink or dry out.
Suggested product:
G.E. Silastic Silicone or equivalent
6. Grout Must not shrink. Can be water mix "mortar" type or epoxy.
Suggested product:
5-Star Epoxy Grout (U.S. Grout Corportation)
3-6-M (Dural International Corporation)
ROCKITE Grout

14
2200 YRM 1230 Specifications

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.

15
Specifications 2200 YRM 1230

Table 3. General Specifications (Continued)

Item or Area Specification

6. Floor Flatness Lift Heights
to 6096 mm (240 in.)
7. Floor Flatness Lift Heights
Above 6096 mm (240 in.)
8. Floor Magnetic Condition
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.
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.
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.

16
2200 YRM 1230
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
System II Wire Guidance Specifications
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) *
17
Pre-Installation Information Form 2200 YRM 1230

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.
* 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).

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").

18
2200 YRM 1230 Pre-Installation Information Form

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: Size(s):
Define off-limit areas for people making wire installation:

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

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