GUIDE WIRE INSTALLATION

R30XMF3 [A169];
R30XMA3 [A185];
C1.0, C1.3 (V30XMU) [A463, A467];
C1.5B (V35XMU) [A464, A468];
C1.8X (V40XMU) [A465, A469];
C1.3 (V30ZMU) [B463];
C1.5 (V30ZMU) [B464];
R30ES [B174];
R30XMS [C174];
R30XMS2 [D174];
N30XMH2 [C210];
V30ZMD [D210];
R30F/FA/FF [E118];
R30XMS3 [E174];
R30XM/XMA/XMF [F118];
R30XM2/XMA2/XMF2 [G118];
R30XM3 [H118]

PART NO. 599596 2200 SRM 1230

 SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• The Service Manuals are updated on a regular basis, but may not reflect recent design changes to the
product. Updated technical service information may be available from your local authorized Hyster®
dealer. Service Manuals provide general guidelines for maintenance and service and are intended for
use by trained and experienced technicians. Failure to properly maintain equipment or to follow in-
structions contained in the Service Manual could result in damage to the products, personal injury,
property damage or death.
• 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 HYSTER APPROVED parts when making repairs. Replacement parts must meet or ex-
ceed 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 flamma-
ble. 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 back-
ground. The CAUTION symbol and word are on yellow background.
 Table of Contents

TABLE OF CONTENTS
General .....................................................................................................................................................................1
Description ...............................................................................................................................................................1
Guide Wire Physical Installation ........................................................................................................................... 3
Equipment ............................................................................................................................................................. 12
Specifications .........................................................................................................................................................15
Wire Slot and Expansion Loop Specifications ................................................................................................. 15
Material and General Specifications ................................................................................................................16
System II Wire Guidance Specifications ..............................................................................................................19
Pre-Installation Information Form ...................................................................................................................... 20

This section is for the following models:

(R30XMF3) [A169];
(R30XMA3) [A185];
C1.0, C1.3 (V30XMU) [A463, A467];
C1.5B (V35XMU) [A464, A468];
C1.8X (V40XMU) [A465, A469];
C1.3 (V30ZMU) [B463];
C1.5 (V30ZMU) [B464];
(R30ES) [B174];
(R30XMS) [C174];
(R30XMS2) [D174];
(N30XMH2) [C210];
(V30ZMD) [D210];
(R30F/FA/FF) [E118];
(R30XMS3) [E174];
(R30XM/XMA/XMF) [F118];
(R30XM2/XMA2/XMF2) [G118];
(R30XM3) [H118]

©2017 HYSTER COMPANY i

"THE
QUALITY
KEEPERS"

HYSTER
APPROVED
PARTS
2200 SRM 1230 General

General
This manual has the correct procedures/methods understanding of this procedure before initial
for installing the guide wire and wire driver for checking of the site. A list of required tools,
operation of the Hyster Wire Guided Vehicles. The equipment and supplies, as well as specifications
procedure is in a sequential step format in the are included in this manual.
order the steps are usually done. Some steps can be
performed out of sequence if the application and For adjustments of the wire driver, refer to the
circumstances indicate. Adequate preparation for section Wire Driver Manual 2200SRM1229.
an economical and durable wire installation
therefore requires a review and complete

Description
There are several things that must be done before An accurate wire path drawing based on the previ-
beginning the actual installation of the guide wire. ously planned aisle layout must be made by either
Careful planning can prevent costly and time con- the customer, the dealer, or Hyster Company. The
suming mistakes. It may be easier and cheaper for purpose of this wire and rack installation drawing
the wire installer to repair any minor floor irregu- is to plan the continuous wire path of up to
larities in the truck path during guide wire instal- 1524 m (5000 ft) per line driver.
lation. It is best the racks can be installed and ap-
proved by the customer and Hyster Company be- The drawing will also be used to show:
fore the installation of the guide wire. If the racks 1. Dimensions for wire routing.
cannot be installed before the guide wire installa-
tion, rack location must be referenced to one or 2. Walls and traffic aisles.
more permanent benchmark points. These points 3. Location of wire driver in a visible area.
must be established and agreed upon by the cus- 4. Total estimated wire length.
tomer and Hyster Company. All dimensions for the
guide wire installation must be referenced to the 5. Total saw cut length.
approved racks or the benchmarks. When the guide 6. Location and type of floor discontinuities.
wire path is known, a physical inspection of the 7. Location of desired expansion loops.
floor must be done by the customer and dealer to
establish the following: 8. Location and capacity of electrical outlets.

1. Location of racks or benchmark points. Possi- 9. The location and type of connectors neces-
ble location of the wire driver. sary to connect a garden hose to the cold wa-
ter source(s).
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 installa-
tion.

1
Description 2200 SRM 1230

If possible, the drawing should include a Make sure the floor is smooth enough for the cas-
12.2 m (40 ft) straight section of guide wire outside ters on the 208.2 liter (55 gal) drum of the vacuum.
the rack aisle for truck testing and alignment. All See Figure 1. Slurry must NOT be dumped in
dimensions must be referenced to the approved sewer or storm drains. Make sure the flow from the
racks or to the agreed on permanent benchmark water source will not be interrupted during the cut-
points and be given in inches or feet and inches. ting operations.
The drawing must be mutually approved by the
customer and Hyster Company. The date and responsibility for installation of the
wire driver must be established at this time. A copy
At least two weeks before the date of installation of of Wire Driver Manual 2200SRM1229 must be
the wire, a pre-installation information form must provided. Make sure the wire driver can be instal-
be completed by the dealer. At this time, the work- led so that it is approximately 1.5 m (5 ft) above the
ing hours will be tentatively scheduled with the floor (bottom of box), will be visible during normal
customer and the amount of customer help (if any) operation and is reasonably protected. It is the cus-
will be determined. If possible, establish cutting tomers responsibility to provide a 115 volt or 230
hours when customer personnel and vehicle traffic volt, 1 amp power source for the wire driver. The
through the cutting area are at a minimum. Alter- wire driver must be installed using conduit for the
nate traffic patterns must be developed to avoid guide wire and the power source per specifications
congestion during installation. See Figure 2. and according to local and national electrical and
building codes. If necessary, the control module can
The amount of normal traffic through the work be removed and stored in a safe place until all work
area, the number of people close enough to the saw is completed.
cutting to require ear protection, protection of elec-
trical and water lines from vehicle traffic, and vent-
ing 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 arrange-
ments for entering and exiting the work site, espe-
cially 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 cus-
tomer 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 Figure 1. Wet Vacuum
installation site to the dump site.

2
2200 SRM 1230 Guide Wire Physical Installation

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 loca-
tion of all off-limit areas.

2. Locate the power and cold water sources. Pro-

vide protection for the power and water lines if
vehicles will cross lines. Install the pedestrian
and other traffic barricades. See Figure 2. Dis-
tribute ear protection devices to customer per-
sonnel 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
Figure 3. Benchmark
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.

Figure 2. Traffic Barricades

3. Locate the benchmark from which all dimen-

sions 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, measure-
ments can be taken from the racks. Otherwise,
measurements must be taken from the perma-
nent 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 condi-
tions so all changes must be approved before in-
stallation continues.
Figure 4. Marking Guide Wire Path

3
Guide Wire Physical Installation 2200 SRM 1230

5. Now is the time to double check all dimensions 8. Mark any floor irregularities which require ex-
and locations against the guide path installa- pansion loops or which must have the slot filled
tion drawing. Any discrepancies and all ques- with silicon elastic instead of grout to allow for
tions must be resolved between the customer, expansion. Metal within 50.8 mm (2 in.) of the
Hyster Company, and installer. saw cut must be removed and the area filled
with epoxy and ground flush with the surface.
6. The chalk line must be exactly located over the In Figure 7, the two metal studs are small
previously marked points. See Figure 5. Slight enough that they were left in the floor and
variations are not allowed due to the critical ground flush with the concrete surface. The
nature of wire straightness. The line must be cracks and expansion joint shown were rem-
snapped so the red chalk is highly visible along edied by filling the slot with caulking for
a continuous path with no breaks. 101.6 mm (4 in.) on each side of the discontinu-
ity.

Figure 5. "Snapping" Chalk Line

7. The entire chalk path must be spray coated us-

ing the specified clear sealer to prevent its be- Figure 6. Spraying Chalk Line
ing erased prior to or during cutting of the slot.
See Figure 6.

4
2200 SRM 1230 Guide Wire Physical Installation

9. The crack shown in Figure 8 had chipped out in

an area in the path of the load wheel. The chip-
ped area had to be ground smooth, cleaned, fil-
led with epoxy, and ground flush with the sur-
face. Grind all high spots and fill all low spots
where the floor tolerance is not within the spec-
ification on the installation 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. Mi-
nor 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 dril-
led 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 sec-
tion. The areas that have caulking make the
guide wire continuity checking and repairs
much easier.

11. Saw alignment is the most critical step in cut-

ting 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 back-
ward along a 6.1 m (20 ft) length, and the steer-
ing adjusted until it tracks along that length
without deviation. This must be done at the be-
ginning of each cut. See Figure 9.

Figure 7. Floor Irregularities

5
Guide Wire Physical Installation 2200 SRM 1230

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 compo-
sition. The depth of cut (slot depth) will also de-
crease 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 infre-
quent 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.

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 Figure 10. Keep Saw on Path
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

6
2200 SRM 1230 Guide Wire Physical Installation

15. The slurry must be vacuumed immediately, to or pipe are some examples. If the conduit or
keep it from re-hardening in the slot. A squee- pipe are still in use, an agreement must be
gee and if necessary, another vacuum is used to made with the customer on the solution to the
keep the slurry from flowing over the floor. See problem. Remove any metal within
Figure 11. 50.8 mm (2 in.) of the slot. Fill the area with ep-
oxy and grind the epoxy flush with the surface.
Cut the slot through the filled area.

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.

Figure 11. Vacuum Slurry Immediately

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

chalk line is difficult to see, a flashlight can be Figure 12. Electric Hand Saw
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 Fig-
ure 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 sec-

tions) to locate any metal in the slot path that Figure 13. Vacuum Slot
was not visible at the surface. Rebar, conduit,

7
Guide Wire Physical Installation 2200 SRM 1230

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 instru-
ment 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

23. When a splice is needed, the "Western Union"

or equivalent method must be used. These spli-
ces 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
Figure 14. Installing the Wire strands of each end and make the "Western Un-
ion" splice. See Figure 16.

24. Solder the wires together and center the

22. Whenever the wire passes around the corner, it shrinkable tubing over the splice. Use the heat
must be taped to prevent chafing. An alterna- gun or hold the soldering iron under the splice
tive method is to provide an expansion loop so to shrink the tubing around the splice until it is
the wire passes around the corner only along tight. Coat the splice with the specified sealant.
the short wire length that will experience very If needed, chisel or saw the slot so it is wide
little movement. See Figure 15. enough for the splice. See Figure 16.

8
2200 SRM 1230 Guide Wire Physical Installation

Legend for Figure 16

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

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.

Figure 17. End of Conduit Covered

Figure 16. Splice

9
Guide Wire Physical Installation 2200 SRM 1230

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 con-
tinuity. An infinity indicates a break in the
wire. A reading of much less than the proper re-
sistance indicates a short circuit between sec-
tions 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.

Figure 19. Caulking Slot

28. Now the grout can be applied to the entire

guide path. With a resin-mixed grout, the con-
sistency 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 fil-
led. Another possible technique is to insert and
Figure 18. Testing Wire 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
27. All cracks and breaks in the floor must have one person can hold the small funnel to direct
been previously marked. The entire guide path the grout into the slot, while the second person
must be inspected. Fill the slot using elastic pours grout into the large funnel. If the grout
caulking for a minimum of 50.8 mm (2 in.) each begins to harden and will not pour, dump the
side at all expansion loops, cracks, and over any batch, clean the tools, and make a new batch.
splices. Fill the slot flush with the surface. Gen-
erally, it is better to use too much than too little
caulking. This step must be completed before
grouting begins. See Figure 19.

10
2200 SRM 1230 Guide Wire Physical Installation

Figure 20. Grouting

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

11
Guide Wire Physical Installation 2200 SRM 1230

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

Figure 22. The guide path will be almost unno-
ticeable in the floor. The extent of the cleanup
must be mutually agreed to by the customer
and the installer. Generally, a water or mop-
ping 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 2200SRM1229.

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 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.

12
2200 SRM 1230 Equipment

Table 1. Equipment (Continued)

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

13
Equipment 2200 SRM 1230

Table 1. Equipment (Continued)

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 For making wire splices.
iron
4. Heat shrinkable tubing, electrical tape, and Sufficient length of specified tubing to insulate
sealant 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. 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 bottle For getting grout mix into slot.
tops and golf tube
8. Knee pads or kneeling pad Recommended for knee protection during grouting
operation.

14
2200 SRM 1230 Equipment

Table 1. Equipment (Continued)

Testing Equipment
1. A volt/ohmmeter (VOM). Beckman HD 100 For checking guide wire continuity and wire
Recommended. Fluke 8020A acceptable at 6.25 driver output. Meter MUST have a reading
KHz or less resolution of 100 uV and an RMS accuracy of ±5
percent at the frequency of the wire driver.

Specifications
WIRE SLOT AND EXPANSION LOOP
SPECIFICATIONS

Figure 23 shows the wire slot and expansion loop

specifications.

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

15
Specifications 2200 SRM 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 16 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

16
2200 SRM 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.

17
Specifications 2200 SRM 1230

Table 3. General Specifications (Continued)

Item or Area Specification

6. Floor Flatness Lift Heights Floor flatness of Face F65 is recommended. In the direction for truck
to 6096 mm (240 in.) 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 Floor flatness of a Face F95 is recommended. In the direction of truck
Above 6096 mm (240 in.) 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.

18
2200 SRM 1230 System II Wire Guidance Specifications

System II Wire Guidance Specifications

Installation Requirements Specifications

Wire Driver Output Requirements
Standard
Frequency 6520 ±10 Hertz
Current 76 to 80 mA

Optional
Frequency 5200 ±8 Hertz
Current 34 to 36 mA

Straightness of Guide Requirements

Maximum Deviation from Straight ±3.0 mm (±0.12 in.) per 3.05 m (10 ft)
Maximum Deviation Change 1.6 mm (0.062 in.) per 1.53 m (5 ft)
Maximum Deviation Between Any Two Points 0.32 mm (0.0125 in.) per 305 mm (1 ft)
Maximum Deviations Per 3.05 m (10 ft) One Deviation.
Floor Flatness Requirements - For Lift Heights F65
to 6096 mm (240 in.)
In Direction of Vehicle Travel *
Maximum Elevation Difference 4.3 mm (1/6 or 0.17 in.) per 1829 mm (72 in.) *
Maximum Elevation Change Rate 3.6 mm (1/7 or 0.14 in.) per 305 mm (1 ft) *
At 90° to Direction of Vehicle Travel *
Maximum Elevation Difference 3.6 mm (1/7 or 0.14 in.) per 1372 mm (54 in.) *
Maximum Elevation Change Rate 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 F95
Above 6096 mm (240 in.)
In Direction of Vehicle Travel *
Maximum Elevation Difference 2.8 mm (1/9 or 0.11 in.) per 1829 mm (72 in.) *
Maximum Elevation Change Rate 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 *

19
System II Wire Guidance Specifications 2200 SRM 1230

Installation Requirements Specifications

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
Floor Topping All iron or floor steel topping must be evenly distrib-
uted 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, Materials must be at least 152 mm (4 in.) below or
Drains 610 mm (24 in.) to the side of the guide wire.
Other Guide Wires With the Same or Different Must be at least 762 mm (30 in.) away from the
Frequencies 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").

Determine fittings required and distance from power and water.

Electrical fittings:
Number and lengths of
electrical cords:

20
2200 SRM 1230 Pre-Installation Information Form

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 □

21
 NOTES

22
 TECHNICAL PUBLICATIONS

2200 SRM 1230 5/17 (1/12)(6/08)(9/05)