Maintenance

WIRE GUIDANCE
SS030BF [A474];
OS030EF [D801];
OS030BF [E826]

PART NO. 550032952 2200 YRM 1471

 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 Yale® dealer. Service Manuals
provide general guidelines for maintenance and service and are intended for use by trained and experienced techni-
cians. Failure to properly maintain equipment or to follow instructions 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. Discon-
nect the battery ground cable on internal combustion lift trucks.

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

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

• Use the correct tools for the job.

• Keep the tools clean and in good condition.

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

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

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

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

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

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

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

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

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

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

TABLE OF CONTENTS

Introduction.......................................................................................................................................................... 1
Steering System and Wire Guidance Electric Components ................................................................................ 2
EPS AC0 Module ............................................................................................................................................ 2
Antenna Module .............................................................................................................................................. 2
LED Operation ............................................................................................................................................ 3
Alignment .................................................................................................................................................... 3
Connection and Configuration .................................................................................................................... 4
Stepper Motor (Multi-turn Steering) ................................................................................................................ 4
Dual Hall Effect Sensor (Smart Steer) ............................................................................................................ 4
Steering Motor Encoder .................................................................................................................................. 4
Centering Proximity Switch ............................................................................................................................. 4
Wire Guidance Parameters ................................................................................................................................. 5
EPS AC0 Module Parameters ......................................................................................................................... 5
Steer Settings ............................................................................................................................................. 5
MTS Gain ............................................................................................................................................... 5
Set Steer 0 POS ..................................................................................................................................... 5
Truck Settings ............................................................................................................................................. 5
Wire Guidance........................................................................................................................................ 5
WG Config .................................................................................................................................................. 5
WG REV OFFSET.................................................................................................................................. 5
Antenna FWD and Antenna RR Module Parameters...................................................................................... 5
WG Config .................................................................................................................................................. 5
Line Frequency ....................................................................................................................................... 5
Lead Regulation ..................................................................................................................................... 5
Lag Regulation ....................................................................................................................................... 5
Acquisition Area...................................................................................................................................... 6
Antenna Height....................................................................................................................................... 6
Strength ACQ. ........................................................................................................................................ 6
Frequency ACQ. ..................................................................................................................................... 6
WG Slow Set .......................................................................................................................................... 6
Wire Guidance Setup .......................................................................................................................................... 7
Set Frequency ................................................................................................................................................. 7
Set Antenna Height ......................................................................................................................................... 7
WG Antenna Calibration ................................................................................................................................. 7
WG Frequency Calibration .............................................................................................................................. 8
Set Steer 0 Position......................................................................................................................................... 8
Reverse Antenna Adjustment.......................................................................................................................... 8
Set WG REV OFFSET .................................................................................................................................... 9
Wire Guidance Operation .................................................................................................................................... 10
Wire Guidance Switch..................................................................................................................................... 10
Wire Acquisition .............................................................................................................................................. 10
Steered Wheel Side .................................................................................................................................... 10
Load Wheel Side ........................................................................................................................................ 11
Wire Guidance Installation................................................................................................................................... 12
Forward Antenna............................................................................................................................................. 12
Reverse Antenna............................................................................................................................................. 13
OS030BF and OS030EF ............................................................................................................................ 13
SS030BF .................................................................................................................................................... 14
Wire Guidance Troubleshooting .......................................................................................................................... 15
EPS AC0 Module Troubleshooting .................................................................................................................. 15
CODE 65516 NODE 6 ................................................................................................................................ 15

©2013 Yale Materials Handling Corp. i

Table of Contents Wire Guidance

TABLE OF CONTENTS (Continued)

WG NOT CALIB.......................................................................................................................................... 15

This section is for the following models:

SS030BF [A474];
OS030EF [D801];
OS030BF [E826]

ii
2200 YRM 1471 Introduction

Introduction
This manual has the procedures for the setup, trou-
bleshooting, and replacement of the wire guidance sys-
tem parts. The electrical adjustments must be com-
pleted as part of the system adjustments for the system
to operate correctly.

NOTE: This lift truck can be operated with the operator

facing the steer tire or the operator facing the load forks.
Throughout this manual, the terms right, left, front, and
rear relate to the viewpoint of an operator standing in
the truck facing the steer tire with the forks trailing. See
Figure 1.

NOTE: Removal and repair procedures for the Master

Drive Unit (MDU) are in the section Master Drive Unit
630 YRM 1460. All mechanical parts of the steering
must be in good condition and correctly adjusted for cor-
rect wire guidance operation. The load wheels MUST
BE THE SAME SIZE and in good condition, and the
bearings must be lubricated and correctly adjusted.

The wire guidance system is capable of performing the

following two different functions:
• Manual operation
Multiturn steer with stepper motor.
Steer with dual hall effect sensor and return spring.
• Wire guidance
The wire guidance system requires two antennas,
one on the drive wheel side and the other on the
load wheel side of the truck. These devices are con-
nected to the EPS AC0 module via CANbus and de-
tect the magnetic field of the underground wire.

A. LEFT SIDE C. FORWARD

B. RIGHT SIDE TRAVEL

Figure 1. Truck Orientation

1
Steering System and Wire Guidance Electric Components 2200 YRM 1471

Steering System and Wire Guidance Electric Components

EPS AC0 MODULE
The EPS AC0 (Figure 2) has two microprocessors con-
nected to the CANbus line. The main microprocessor
operation is constantly monitored by the slave micropro-
cessor, so that the main functions are controlled twice.
MOSFET technology (internal transistors) is used to
control the three-phase AC steering motor. The EPS
AC0 module is equipped with a steer status contact
(pins A4 and A5) to disable the traction and to enable
the electromagnetic brake when a steer alarm occurs.
Two contacts are connected in series between pins A4
and A5 for safety reasons. The main microprocessor
(master) controls the first contact while the slave micro-
processor controls the second contact.

Technical specifications:
• Digital control through two microprocessors which are
both connected via CANbus
• Encoder interface Figure 2. EPS AC0 Module
• Interface for stepper motor or dual hall effect sensor
• Refer to Table 1 for additional specs ANTENNA MODULE
Table 1. AC0 Module Technical Specifications The antenna is a device supporting the wire guidance
function. It has an embedded microprocessor, pro-
Digital inputs 3 grammable digital filters, and Automatic Gain Control
Logic (AGC) to convert and interpret the sensed in-
NPN outputs (max 24V 3
ductive field into the complete information needed to
200mA)
control the truck when automatically guided on the
NPN output max 90V 2A 1 wire. The embedded Automatic Gain Control (AGC)
Double safety relay 8kHz with PWM aligned compensates for differences in depth and current in
inside Operating with the center the wire.
frequency The Smart Antenna supplies information composed of
Maximum temperature of 78°C three static components:
inverter 1. The lateral deviation (SIDE ERROR) of the antenna
barycenter against the wire.
Protection IP54 2. The angle (APPROACH ANGLE) of the longitudinal
axle of the antenna against the wire.
3. The strength of the inductive field (FIELD
STRENGTH).

2
2200 YRM 1471 Steering System and Wire Guidance Electric Components

See Table 2 for the technical specifications: Alignment

Table 2. Antenna Module Technical Specifications Two antennas are mounted on the truck, one on the fork
side of the truck under the driver platform (reverse an-
Supply voltage range 13V dc - 18V dc tenna), and one on the drive wheel side of the truck in
front of the traction wheel (forward antenna). The two
Supply current 120 mA dc
antennas must be perfectly aligned with one another
Frequency and current in 5.2 kHz (35 mA RMS) and oriented as shown in the figure below. See Fig-
these wire modes 5.2 kHz (78 mA RMS) ure 4.
6.25 kHz (78 mA RMS)
7 kHz (78 mA RMS)
9.1 kHz (78 mA RMS)
10 kHz (78 mA RMS)
Frequency tolerance ±20 Hz
Wire current tolerance ±15%

LED Operation
Each antenna is equipped with a built-in LED See Fig-
ure 3. These LED’s are used to show the connection
status to the Wire Guidance system by a sequence of
flashes.
• When the LED flashes (ON/OFF pulses) the antenna
is fed and the software processes the data.
• When the LED flashes and is mainly ON the antenna
does not detect the wire field.
• When the LED flashes and is mainly OFF the antenna
detects the wire field.
• When the LED flashes and emits pulses one after the
other the antenna is alarmed.

1. BRACKET ASSEMBLY
2. ANTENNA
3. LED
1. GUIDE WIRE
Figure 3. Antenna LED Location (Reverse shown) 2. REVERSE ANTENNA
3. REVERSE ANTENNA CABLE
4. FORWARD ANTENNA CABLE
5. FORWARD ANTENNA

Figure 4. Aligned Antennas

3
Steering System and Wire Guidance Electric Components
Connection and Configuration
The antennas communicate with the EPS AC0 module
through the CAN BUS communication system. Each
antenna has a cable with 5 wires and a sheath. The
grey wire (MODE) is used to specify the position of the
antenna on the truck. See Figure 5. The connections
are as follows:
• Reverse Antenna configuration: Connect the MODE
(Grey) wire to Ground (GRN) connection.
• Forward Antenna configuration: Connect the MODE
(Grey) wire to a VDD (Pink) connection.
Figure 5. Antenna Connections
The antennas will both need to be oriented such that
they are mounted with the wire coming out of the side
nearest the right side of the truck, as seen by an ob-
server on the forks side of the truck facing the operator
platform. The face plate of the antenna should be near-
est to the ground. See Figure 4.
STEPPER MOTOR (MULTI-TURN
STEERING)
The stepper motor is used as a control device in Multi-
turn steering systems without limit switches. See Step-
per Motor (Multiturn) in Steering System 1600 YRM
1462. It is used as a generator since it acts as an alter-
nating current generator if the shaft is rotated manually.
The rotor magnet rotation creates a sinusoidal electro-
magnetic force divided into two phases shifted 90° out
4
2200 YRM 1471
of phase. The amplitude and the frequency are propor-
tional to the rotor revolving speed. The logic analyzes
the signal in the two phases to differentiate the rotation
direction.
DUAL HALL EFFECT SENSOR (SMART
STEER)
The Dual Hall-Effect sensor is used as a control device
in the Smart Steer steering system. It is contained in
the same case and sends two complementary signals.
See Analog Input Sensor (Smart Steer) in Steering
System 1600 YRM 1462.
STEERING MOTOR ENCODER
The steering motor encoder is located on the top of
the steer motor. When the steering motor encoder is
enabled, the steering wheel position sensor initializes
the encoder count and the steering wheel is centered,
see the Centering Proximity Switch section. If after the
self-centering the steering wheel is not perfectly cen-
tered, increase or decrease the value of the parameter
SET STEER 0 POS in Settings/Steer Settings. Once
initialized, the steer encoder sends pulses that are
counted by the software. In this way the controller al-
ways knows the absolute position of the steered wheel.
The encoder pulse count allows the system to control
the steered wheel self-centering when the truck enters
an aisle or when both antennas have acquired the wire
in wire guidance mode (lock-on mode). In case of an
inconsistency between the status of the wheel position
sensor and the steering motor encoder pulse count, the
EPS AC0 module throws the “position error” alarm.
CENTERING PROXIMITY SWITCH
The centering proximity switch is fixed to the steering
unit support plate. When the sensor is enabled, the
EPS AC0 module turns the steering unit clockwise or
counterclockwise. The direction depends on whether
the steering wheel centering proximity switch reads the
cam on the steer crown gear (enabled) or not (disabled).
When the sensor changes its status from ON to OFF or
from OFF to ON the wheel is centered and the steer-
ing motor encoder count is initialized. In case of an
inconsistency between the status of the wheel position
sensor and the steering motor encoder pulse count, the
EPS AC0 module throws the “position error” alarm.
2200 YRM 1471
Wire Guidance Parameters
EPS AC0 MODULE PARAMETERS
Steer Settings
MTS Gain
Steering unit rotation speed (MDU) when the steering
wheel is turned quickly. It establishes the maximum
rotating speed of the steering unit.
• 0 = low speed
• 9 = high speed
Set Steer 0 POS
In wire guidance mode, the truck can move parallel to
the wire in the traction wheel direction (mean value of
parameter DIAGNOSTICS/WG DIAGNOSTICS/SIDE
ERROR FWD higher or lower than 0). This param-
eter compensates for the side to side deviation by
changing the straight ahead angle of the drive wheel
by a small amount. In manual mode (RTC or MTS), it
also determines the angle of the drive wheel after the
self-centering phase at key-on position. Value adjusts
in increments of 1 mV.
Truck Settings
Wire Guidance
When enabled, the truck expects antennas to be in-
stalled and will enable the driver’s wire guidance switch.
• 0 = off
• 1 = wire guidance enabled
WG Config
WG REV OFFSET
In wire guidance mode the truck can move parallel to
the wire in the load wheel direction (mean value of pa-
rameter DIAGNOSTICS/WG DIAGNOSTICS/SIDE ER-
ROR RR higher or lower than 0). Side to side deviation
can be compensated for through this parameter. Value
modifiable in increments of 20 mV.
Wire Guidance Parameters
ANTENNA FWD AND ANTENNA RR
MODULE PARAMETERS
WG Config
Line Frequency
The wire frequency must be set in both the Fwd and Rr
antennas.
• 5.20 kHz
• 6.25 kHz
• 7.00 kHz
• 9.10 kHz
• 10.00 kHz
Lead Regulation
It adjusts the derivative contribution to an embedded
PID corrective network applied to the lateral deviation of
the antenna. It is used to avoid oscillations (instability)
during truck operation at high speed in wire guidance
mode. It is advisable to set the LEAD parameter at the
same level on both antennas (do the same with the LAG
parameter on both antennas).
• 0 = no lead (derivative) correction
• 9 = maximum lead (derivative) correction
Lag Regulation
It adjusts the integral contribution to an embedded PID
corrective network PID applied to the lateral deviation
of the antenna. It is used to avoid oscillations (instabil-
ity) during truck operation at high speed in wire guid-
ance mode. It is advisable to set the LAG parameter at
the same level on both antennas (do the same with the
LEAD parameter on both antennas).
• 0 = no lead (derivative) correction
• 9 = maximum lead (derivative) correction
5
Wire Guidance Parameters 2200 YRM 1471

Acquisition Area Strength ACQ.

Acquisition area can be thought of as a spotlight. The It enables the magnetic field acquisition with the an-
lower the setting, the larger this spotlight will be. The tenna aligned on the wire. In PC Service tool, acqui-
antenna will acquire when the wire falls within this area. sition will need to be performed independently for each
Too large of an area will cause the truck to think the wire antenna.
has been acquired too soon which can lead the truck • ON = acquisition start
to travel too quickly while still correcting its alignment
shortly after acquisition, and the truck may need to slow Frequency ACQ.
down to realign on the wire. Setting the area too small
It enables the line frequency acquisition for non-stan-
(a high acquisition area setting) may cause the truck to
dard frequencies. In PC Service tool, acquisition will
take longer to acquire the wire.
need to be performed independently for each antenna.
• 0 = the antenna is very insensitive and very high field
• ON = acquisition start
strength is necessary to acquire the wire.
• 9 = the antenna is very sensitive and very low field WG Slow Set
strength is sufficient to consider the wire to be ac-
quired. This area sets the magnetic field threshold Enables an additional traction speed reduction when
that allows the antenna to acquire the wire. the wire is sensed. This can help if the wire acquisi-
tion seems difficult, especially when wire acquisition is
Antenna Height usually attempted at steep angles.
• ON = slow down upon wire sense
Antenna Height represents the distance in millimeters
• OFF = default setting
of the antenna base from the wire plus 11 mm (where
11 mm is the distance from the faceplate of the antenna
to the center of the internal antenna coil). For example,
41mm (measured antenna height) + 10mm (wire depth)
+ 12mm (antenna coil) = 63mm. 6 will be used is this
case, per selection below.
• 0 = 30 mm
• 1 = 35 mm
• 2 = 40 mm
• 3 = 45 mm
• 4 = 50 mm
• 5 = 55 mm
• 6 = 60 mm
• 7 = 65 mm
• 8 = 70 mm
• 9 = 75 mm

6
2200 YRM 1471 Wire Guidance Setup

Wire Guidance Setup

NOTE: It is recommended to preform Wire Guidance • 1 = 35mm
Setup for the following: • 2 = 40mm
• The forward or reverse antenna or steer controller is • 3 = 45mm
replaced. • 4 = 50mm
• The drive wheel or load wheel is replaced. • 5 = 55mm
• 6 = 60mm
SET FREQUENCY • 7 = 65mm
• 8 = 70mm
1. Enter the WG CONFIG menu.
Level 6 will be used in the example shown in Step 1.
2. Scroll to FWD ANT FREQ (forward antenna fre-
quency). Set and save the line frequency for the 4. Scroll to WIRE DEPTH REV (wire depth reverse)
forward antenna (drive wheel side) value as follows: and repeat Step 1 though Step 3.
• 0 = 5.2khz
• 1 = 6.2khz 5. Recycle the key switch.
• 2 = 7.0khz
• 3 = 9.1khz WG ANTENNA CALIBRATION
• 4 = 10.0khz
1. Align the center of the forward and reverse anten-
3. Scroll to REV ANT FREQ (reverse antenna fre- nas over the center of the wire.
quency). Set and save the line frequency for the
NOTE: Ensure to align the reverse antenna itself, not
reverse antenna (fork side) value as follows:
the bracket.
• 0 = 5.2khz
• 1 = 6.2khz 2. Enter the SETUP menu.
• 2 = 7.0khz
• 3 = 9.1khz 3. Scroll to WG CONFIG and press button 2.
• 4 = 10.0khz
4. Use buttons 1 and 3 to scroll to FIELD STR CALIB,
4. Recycle the key switch. and press 2.

SET ANTENNA HEIGHT 5. Use button 1 or 3 to change the setting to ON.

1. Measure the forward antenna height in millimeters
(from the ground to the bottom or the lowest point of
the antenna), then add the depth of the wire (10mm
is a common value), and then add 12mm (distance
from the bottom of the antenna to the internal coil
of the antenna). For example: 41mm (measured
antenna height) + 10mm (wire depth) + 12mm (an-
tenna coil) = 63mm.
2. Enter the WG CONFIG menu.
3. Scroll to WIRE DEPTH FWD (wire depth forward).
Set and save the antenna height, which is obtained
from Step 1, value as follows:
• 0 = 30mm
6. Press button 5 twice to save.
7. Press button 4 to exit the setup menu.
8. Recycle the key switch.
9. Check to ensure that the field strength is properly
calibrated. Enter the WG DIAGNOSTIC menu and
compare the following:
• FIELD STRENG FWD (field strength forward)
should be approximately the same as ALIGN
STRG FWD (align strength forward).
• FIELD STRENG REV (field strength reverse)
should be approximately the same as ALIGN
STRG RR (align strength reverse).

7
Wire Guidance Setup
WG FREQUENCY CALIBRATION
The WG Frequency Calibration procedure allows the
antennas to detect the wire frequency automatically. It
should be used when either the wire driver is set to a
non-standard frequency, or if the truck is having unusual
difficulty calibrating field strength.
1. Align the center of the forward and reverse anten-
nas over the center of the wire.
NOTE: Ensure to align the reverse antenna itself, not
the bracket.
2. Enter the SETUP menu.
3. Scroll to WG CONFIG and press button 2.
4. Use buttons 1 and 3 to scroll to FREQUENCY
CALIB, and press 2.
5. Use button 1 or 2 to change the setting to ON.
6. Press button 5 to save.
7. Press button 4 to exit the setup menu.
8. Recycle the key switch.
NOTE: Performing this procedure may cause the truck’s
stored Field Strength values to become invalid. WG
Antenna Calibration must be performed after the WG
Frequency Calibration.
SET STEER 0 POSITION
1. Acquire the wire in the forward direction.
2. Enter the WG DIAGNOSTIC menu and scroll to
SIDE ERROR FWD. Drive slow (approximately
1mph) in the forward direction while observing the
SIDE ERROR FWD (side error forward). SIDE
ERROR is the distance in millimeters between the
center of the antenna and the wire. When viewing
from the fork end, the value is positive if the an-
tenna is on left of the wire and negative if on the
right side of the wire.
NOTE: Recommended minimum of traveling distance
is 300ft or the longest available distance.
3. If the magnitude of the SIDE ERROR is approxi-
mately the same for the positive and negative skip
8
2200 YRM 1471
the remaining steps in the Set Steer 0 Position sec-
tion. This means that the front antenna is tracking
about the wire, not on one side of the wire, in for-
ward direction.
4. If the magnitude of the SIDE ERROR is more posi-
tive than negative this means that the front antenna
is tracking on the left side of the wire. Increase the
SET STEER 0 POS (set steer zero position) in the
STEER SETTING menu. Save and recycle the key
switch after making this change then repeat Step 2
until step Step 3 is met.
5. If the magnitude of the SIDE ERROR is more nega-
tive than positive this means that the front antenna
is tracking on the right side of the wire. Decrease
the SET STEER 0 POS (set steer zero position) in
STEER SETTING menu. Save and recycle the key
switch after making this change then repeat Step 2
until step Step 3 is met.
REVERSE ANTENNA ADJUSTMENT
1. Acquire the wire in the forward direction.
2. Drive slow (approximately 1 mph) in the forward di-
rection for 50 ft.
CAUTION
Before adjusting the lateral position of the rear
antenna, use blocks and chains on the upright
weldments and operator platform so they cannot
move. Make sure the moving parts are attached
to a nonmoving part. Use blocks and chains to
prevent movement of the operator platform. After
the Platform has been raised to a level that allows
a technician to work under the Platform, the key
switch should be in the off position. Also, the
battery should be disconnected while a technician
is working under the Platform.
3. Move the reverse antenna (fork side) laterally so
that its center is over the center of the wire as
needed. In order to move the antenna, bolt 1 and
nut 10 in Figure 6 must be loosened (quantity of 4
each). Once the antenna is in the desired position,
torque the bolt and nut to 13 N•m (9.6 lbf ft).
2200 YRM 1471 Wire Guidance Setup

SET WG REV OFFSET

1. Acquire the wire in the forward direction.

2. Enter the WG DIAGNOSTIC menu and scroll

to SIDE ERROR RR. Drive slow (approximately
1mph) in the reverse direction (forks leading) while
observing the SIDE ERROR RR (side error re-
verse). SIDE ERROR is the distance in millimeters
between the center of the antenna and the wire.
When viewing from the fork end, the value is posi-
tive if the antenna is on left of the wire and negative
if on the right side of the wire.

NOTE: Recommended minimum of traveling distance

is 300ft or the longest available distance.

3. If the magnitude of the SIDE ERROR is approxi-

mately the same for the positive and negative skip
the remaining steps in the Set WG REV OFFSET
section. This means that the reverse antenna is
tracking about the wire, not on one side of the wire,
in reverse direction.

4. If the magnitude of the SIDE ERROR is more pos-

itive than negative this means the reverse antenna
1. CAPSCREW 7. SUPPORT is tracking on the left side of the wire. Decrease the
2. BRACKET 8. CAPSCREW WG REV OFFSET (wire guidance reverse offset) in
3. NUT 9. ANTENNA the WG CONFIG menu. Save and recycle the key
4. WASHER 10. NUT switch after making this change then repeat Step 2
5. WASHER 11. WASHER
6. CLAMP 12. CONDUIT CLIP until step Step 3 is met.

Figure 6. Wire Guidance Bracket Assembly
5. If the magnitude of the SIDE ERROR is more neg-
ative than positive this means that the reverse an-
tenna is tracking on the right side of the wire. In-
crease the WG REV OFFSET (wire guidance re-
verse offset) in the WG CONFIG menu. Save and
recycle the key switch after making this change then
repeat Step 2 until step Step 3 is met.

9
Wire Guidance Operation 2200 YRM 1471

Wire Guidance Operation

WIRE GUIDANCE SWITCH
The wire acquisition starts by pressing the top of the
wire guidance switch (“ON”). See Figure 7. The pilot
light starts blinking and the buzzer emits an intermittent
sound. When the antenna “acquires” the wire field, the
manual operation is disabled, the buzzer emits a long
sound and then stops. The switch light stays on. To
disable wire guidance mode, press the bottom of the
wire guidance switch (“OFF”). The buzzer emits a long
sound and then stops. The switch light turns off.
When a new system is installed it may be necessary
to adjust the alternating current signal strength sent by
the line driver according to the application conditions
and the wire resistance. To adjust the signal strength,
connect a multimeter (Amp. a.c.) in series with the wire,
and turn the line driver potentiometer until the correct
current value is obtained (78 mA/35 mA).

Figure 8. Approaching Guide Wire

1. DISPLAY
2. WIRE GUIDANCE SWITCH

Figure 7. Wire Guidance Switch

WIRE ACQUISITION
Steered Wheel Side
In manual mode the truck is programmed to perform
traction at full speed according to the traction perfor-
mance selected. By pressing the wire guidance mode
push button ON, the truck speed is limited to 3.21 km/h
(2.0 mph) once the wire is in range. See Figure 8.
When the forward antenna acquires the wire the EPS
AC0 module disables the steer and starts controlling the
self-aligning. See Figure 9 and Figure 10. When both
antennas are perfectly aligned with the wire the truck Figure 9. Steering Disabled
can perform traction at full speed. See Figure 11. If the
truck approaches the wire at a too high speed or if inter-
sects the wire with a too wide angle (higher than 30°),
the wire guidance mode cannot be enabled.

10
2200 YRM 1471 Wire Guidance Operation

wire is at an angle of about 10°, the reverse antenna

will overshoot the wire by a few centimeters before the
steered wheel turns about 90° to position the forward
antenna nearly over the wire. This step may occur
up to three times depending on the initial approach
angle. When the forward antenna and reverse antenna
acquire the wire, the truck stops to allow the steered
wheel to reach an angle of about 0°. See Figure 14.
Then the steered wheel aligns the antenna fwd with
the wire. This step takes about 2 seconds. When both
antennas are perfectly aligned with the wire the truck
can perform traction at full speed. See Figure 15. If the
truck approaches the wire at a too high speed or if in-
tersects the wire with too wide of an angle (higher than
10 degrees), wire guidance mode cannot be enabled.

Figure 10. Guide Wire Aquired

Figure 12. Approaching Guide Wire

Figure 11. Locked On Guide Wire

Load Wheel Side

In manual operation the truck is programmed to perform
traction at full speed according to the traction perfor-
mance selected. By pressing the wire guidance mode
push button ON, the truck speed is limited to 3.21 km/h
(2.0 mph). See Figure 12. When the reverse antenna
acquires the wire the EPS AC0 module disables the
steer handle and starts controlling the self-aligning.
See Figure 13. In this step the reverse antenna is very
near the wire and the truck stops to allow the steered
wheel to reach the necessary steering angle (about
90°) for the forward antenna to approach the wire. If the Figure 13. Steering Disabled

11
Wire Guidance Installation 2200 YRM 1471

Figure 14. Guide Wire Aquired

Figure 15. Locked On Guide Wire

Wire Guidance Installation

FORWARD ANTENNA
The forward antenna is bolted directly to the chassis in
front of the traction wheel. This antenna is fixed and is
not adjustable. See Figure 16 and Figure 17 for mount-
ing illustrations.

Legend for Figure 16

1. CAPSCREW
2. CLAMP
3. NUT
4. BRACKET
5. CONDUIT CLIP
6. SPACER
7. ANTENNA
8. CAPSCREW
9. WASHER
10. WASHER
11. NUT

Figure 16. Forward Antenna Bracket Assembly

12
2200 YRM 1471 Wire Guidance Installation

for the mast installation procedure. The wire guidance

mounting bracket assembly should be fully assembly
before installation on the truck. Take care not to dam-
age the antennas or harness during installation.

1. Before mounting the rear wire guidance bracket

assembly to the mast, the sensor must first be
mounted to the bracket. See Figure 18.

1. ANTENNA BRACKET ASSEMBLY

2. CHASSIS
3. ANTENNA HARNESS
4. HARNESS BRACKET

Figure 17. Forward Antenna Mounting

REVERSE ANTENNA
The reverse antenna is mounted under the driver plat-
form. This antenna assembly has slotted holes used for
adjusting to achieve proper alignment.

OS030BF and OS030EF

1. CAPSCREW 7. SUPPORT
CAUTION 2. BRACKET 8. CAPSCREW
Before installing the rear antenna, use blocks and 3. NUT 9. ANTENNA
4. WASHER 10. NUT
chains on the upright weldments and operator plat- 5. WASHER 11. WASHER
form so they cannot move. Make sure the moving 6. CLAMP 12. CONDUIT CLIP
parts are attached to a nonmoving part. Use blocks
and chains to prevent movement of the operator Figure 18. Reverse Antenna Bracket Assembly
platform. After the Platform has been raised to a
level that allows a technician to work under the Plat- 2. Raise the platform to a height that will allow for easy
form, the key switch should be in the off position. access underneath the platform. Support the plat-
Also, the battery should be disconnected while a form with a hoist and chain.
technician is working under the Platform. 3. At the base of the mast there are four capscrews
NOTE: If mast disassembly is required for a truck that is that secure the mast to the chassis frame. Remove
equipped with wire guidance be sure to reinstall the wire the two inner capscrews and washers as shown in
guidance bracket assembly once the mast installation Figure 19.
is complete. See Mast, Repair 4000 YRM 764 Install,

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Wire Guidance Installation 2200 YRM 1471

guidance bracket assembly once the mast installation

is complete. See Mast, Repair 4000 YRM 764 Install,
for the mast installation procedure. The wire guidance
mounting bracket assembly should be fully assembly
before installation on the truck. Take care not to dam-
age the antennas or harness during installation.

1. Before mounting the rear wire guidance bracket

assembly to the mast, the sensor must first be
mounted to the bracket. See Figure 20.

1. WASHER
2. CAPSCREW
3. ANTENNA BRACKET ASSEMBLY
4. MAST ASSEMBLY

Figure 19. Mounting Bracket and Wire Harness

Routing

4. Position the bracket assembly onto the mast and

align the holes in the bracket with the bolt holes in
the mast. Reinstall the two capscrews and washers
and torque to 225 N•m (166 lbf ft). See Figure 19.

5. The wire guidance wire harness is to travel up the

center of the mast following the hydraulic hose as 1. CAPSCREW 6. SUPPORT
shown in Figure 19. Use clamp straps to secure the 2. BRACKET 7. WASHER
3. NUT 8. NUT
wire harness to the hose. Allow the harness to fol- 4. WASHER 9. ANTENNA
low the hydraulic hose to the mast cylinder where 5. WASHER 10. CAPSCREW
it will travel up the mast cylinder until it reaches the
grommet and opening to the chassis. Use appropri- Figure 20. Wire Guidance Bracket Assembly
ate clamp straps to secure the harness to the mast
cylinder. 2. Raise the platform to a height that will allow for easy
access underneath the platform. Support the plat-
6. Connect the chassis wire guidance harness to the form with a hoist and chain.
antenna harness.
3. At the base of the mast there are four capscrews
SS030BF that secure the mast to the chassis frame. Remove
the right side inner capscrew and washer. See Fig-
NOTE: If mast disassembly is required for a truck that is ure 21.
equipped with wire guidance be sure to reinstall the wire

14
2200 YRM 1471 Wire Guidance Troubleshooting

4. Position the wire guidance harness support bracket

onto the mast as shown in Figure 21. Reinstall
the capscrew and washer and torque to 225 N•m
(166 lbf ft). Secure the opposite end of the
wire guidance support bracket onto the existing
bar between the base arms with the capscrew
and washer. Torque the capscrew to 19.2 N•m
(14 lbf ft).

5. Mount the antenna bracket assembly to the existing

bar with the two capscrews as shown in Figure 21.
Torque the capscrews to 19.2 N•m (14 lbf ft).

6. Secure the harness to the support bracket with con-

duit clips along the bracket as shown in Figure 21.
The wire guidance harness should travel up the hy-
draulic hose in the center of the mast. Use strap
clamps to secure the harness to the hose. Allow
the harness to follow the hydraulic hose to the mast
1. WASHER cylinder where it will travel up the mast cylinder until
2. CAPSCREW reaches the grommet opening to the chassis. Use
3. CAPSCREW appropriate clamp straps to secure the harness to
4. CAPSCREW the mast cylinder.
5. WASHER
6. EXISTING BAR 7. Connect the chassis wire guidance harness to the
7. ANTENNA BRACKET ASSEMBLY
8. SUPPORT BRACKET antenna harness.
9. MAST ASSEMBLY

Figure 21. Mounting Bracket and Wire Harness

Routing

Wire Guidance Troubleshooting

EPS AC0 MODULE TROUBLESHOOTING
CODE 65516 NODE 6
Missing Antenna – Wire guidance is enabled through
the display, but one or both of the antennas are dis-
connected. Check software version for each antenna
through the display:
4. If either software version says “NOT AVAILABLE!”
check the connection to that antenna.
WG NOT CALIB
The antennas need to be calibrated for field strength.
Perform the WG Antenna Calibration procedure to clear
the message.

1. Enter the service menu. Refer to AC Motor Controller 2200 YRM 1466 for fur-
ther troubleshooting.
2. Enter the software version.

3. Scroll to ANTENNA FWD and ANTENNA RR.

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 NOTES

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