UCA TXM Introductory-Final (5-1-19)

5/15/2019
TXM Introductory Service Training

TXM – 3 Wheel Sit-down Electric Counterbalance
© 2017, UniCarriers Americas Corporation. All rights reserved. Content is privileged and confidential.
TXM Introductory Service Training
Instructor for this class is:
Your name here
1
5/15/2019
3 Wheel Electric Counterbalance
TXM Model – Produced in Houston, Texas by MCFA
TXM
TXM
TX30M
TX35M
TX40M
3 Wheel Electric Counterbalance

Data Tag located on Right Front Corner of Top Panel
TXM
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5/15/2019
What's new for UniCarriers?
- STANDARD -
• Electronic Power Steering system
• Electronic Park Brake
• Ramp Hold feature
• Brakes and Transfer Case
• Meter Panel Display
• Rubber Floor Mat
• Counterweight mounted control
modules
• Lift lever mounted main horn button
• Rear handgrip w/horn
• Controlled Cornering Speed
• Laptop access for Technicians
What's new for UniCarriers?
- OPTIONS -
• Foot Direction Pedal (option) –
operators control speed and direction
with a single foot control
• U.L. Type EE Rating (option)
• Drive-In Racking Overhead Guard
(option)
• Forward or Reverse Activated Blue
Lights (option)
• Freezer Package (option) for operation
in environments as low as 14o F (-10o C)
• Battery Rollers (option)
• Fingertip Control console (option)
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Features
Operator Presence System
PDS = 4 Wheel Models

IPS = 3 Wheel Models
Controlled Cornering Speed

ON/OFF only …… NO speed parameter setting
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Features
• Smaller steering wheel with
“spinner” knob standard
• Display- user friendly
• Park brake switch
• Brake fluid reservoir location
(DOT 3 or 4 brake fluid)
• Brake pedal
• FNR / Light combo
• Horn button located on Lift
Lever, not steering wheel
• E-stop button
• Rubber floor mat
Display Features
• Turtle mode 4 wires for display since it’s on the CANbus (truck
• Speed indicator* will still work if the display goes out)
• Date/Time/Hr meter
• Steer angle indicator
• Fault codes
• Multi color BDI
* Max speed 9.9 MPH
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Features
Removable, locking, spring-loaded Tow Pin
Motor Locations
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Pump Motor
No encoder
on this motor
Hydraulic System
Hydraulic Tank Detail
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Traction Motor
This motor has

an Encoder
(Sensor Bearing)
Drive Motors & transfer cases

• Side by side transfer units
• 5 lug hub
• Magnetic type automatic

park brake
• Encoder bearings in each

Drive Motor
• Replaceable Temperature
Sensors
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Park Brakes
Switch
• Magnetic type automatic park brake for improved safety
• Park brake switch on dash
Manual release of Park Brake
(1) Loosen the brake

plate mounting bolts,
and remove
the brake plate.
(2) Tighten the bolts
again.
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Park Brakes
This emergency brake release tri-angle

is installed on every truck off-factory.
The brake release protocol is mentioned
in the OMM, since the Technician must
be aware on how to release the park
brake in case of emergency.
This tri-angle is NOT easy to install to

release the park brake, since the mast
is partially blocking the access and
there is almost no space to use an
Allen-key to tighten these bolts.
Park Brake Misuse
When the park brake is applied by pushing the brake button during
driving, the controller will slow the traction motor down by auto-
regen until 0 MPH occurs and then apply the park brake. Thereby
avoiding unnecessary wear or damage to park brake components.
When the key switch is turned OFF during driving, this auto regen
will not work and the “negative park brake system” will apply with
the results shown on the next slide.
This will be categorized under “operator abuse”.
BEWARE: The left side brake is installed under a

different angle, than the right side !
NOTE: There are two part-numbers for the

traction motors, and the brake assemblies.
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5/15/2019
Park Brake Misuse

This will happen when you turn off the key switch while the
truck is still driving! Automatic park-brake will be applied.
New condition Burnt condition
Transfer Case
• Oil immersed Wet Disc Brakes

• Wet Disc Brakes and Reduction
Gears in same compartment
• Fully enclosed Transfer Case
• Long service interval
• Ideal for special applications
Fishery
Food banks
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Transfer Case
•Left side shown
Wheel Brakes
• Brake Lever
• Adjusting Bolt
• Bleeder Screw
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5/15/2019
Wheel Brakes
•Brake Cylinder Brake Push Pin
Wheel Brakes
Brake push pin Lever side Brake plate side
Beware, the O-ring is positioned off-center

on the pin. Do not reverse when installing !
NOTE: Beveled edge goes inward to contact the Brake Plate. Convex
end goes outward. This end is pressed against by the Brake Lever.
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Wheel Brakes
Guide Pin
Wheel Brakes
Have the new friction plate saturate with the Sinter friction plate
specified front axle oil, hours BEFORE installation. NYK 75 series
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5/15/2019
Steering System
Max turns from lock-

to-lock is now 6 turns
for better feeling.
Because of the
smaller outer-
dimension, the horn
button has been re-
located.
Steering System (Horn locations)

MC: on the lift knob at lift lever (integrated)
FC: on the armrest when having fingertip control
STD: the grab handle on the right-hand rear over-

head guard leg will also have a horn button.
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Steering System
1.Steering wheel
2.Steering unit
3.EPS controller
4.EPS motor
5.Rear axle
assembly
6.Steering angle
potentiometer
Steering System
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Steering System
TFD = Tactile Feedback Device
Steering System
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5/15/2019
Steering System (EPS)
• Steer by Wire
• EPS motor 600W
• Increased operator comfort
• Low steering effort
• Small steering wheel
• Low energy consumption
• Steering on demand
• Steer Axle is mounted on the
Chassis
No need to grease before 3-wheel configuration

Installation. Greased by North America = 600W
Splash lubrication.
(Helical splines)
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Steering System
Brush material:
Class H-100
600W motor
Lmax =20mm
Lmin = 9mm
Spring-force - 600W = 5N
Steering System
Be aware of the “D”

shaped coupling when
mating the steer-angle
sensor on top of the
steer axle.
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Steering System
1. The steer angle potentiometer should be installed like in above image. The
wires should be facing the left side. position the sensor mid-mid of the
slot-holes.
2. Make sure the wheels are visually in the center position.
3. NOTE: “D” shaped shaft of steer angle sensor.
Steering System
A = stopper bolt steer-axle
B = mechanical stop on housing
A B
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5/15/2019
Steering System
Here’s the drain plug.
This is an end-cap for the

hollow shaft.
Electronic Steering System (EPS)
What does it do?

• Electronic Power Steering
• EPS controller is a motor
drive controller.
• It drives the DC steer motor
according to the steering
and tire angle inputs.
• It also monitors malfunctions
of the motor and its
condition.
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Only the U and W phase are used. The concept of controlling
the standard DC permanent magnet motor , to turn in both directions,
is done by an H-Bridge concept. This EPS module controls the signal
from the steer-angle-sensor.

EPS internal switching
A1 & B2 are controlled by PWM , where
A2 & B1 are switched 100% ON – or 100% OFF.
In this case we can control the EPS motor rotation direction & the motor speed.
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Contactors and Fuses
(1) 500 A Line fuse

(2) 60 A PS fuse
(3) 10 A Lamp fuse Line contactor
(4) 10 A Key fuse
PS contactor
Controllers, Logics and Inverters

EPS Controller
L&R Traction Inverters
Pump Inverter
Meter panel Assembly
Logics Unit
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5/15/2019
Modules mount directly to the Counterweight
Use Dielectric grease

when installing an inverter
on the Counterweight
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5/15/2019

What do they do?
• Drive the AC induction motors according to the motor control command from the logic unit.
• Monitors malfunctions of the motor and its condition. When a malfunction occurs, it stops the motor and
informs to the logic unit.
• Battery DC current is converted into AC current for the traction and pump motors through the Insulated
Metal Substrate (IMS) module holding the MOS-FETs.
L Traction Inverter R Traction Inverter Pump inverter
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5/15/2019

What does it do?
• Controls all the jobs for the forklift based on the operators input.
• Sends command signal to the traction inverters based on FNR lever and accelerator pedal position at the same time it
monitors malfunctions of the traction system.
• Sends signal command to the pump inverter based on hydraulic lever micro switch inputs.
• Sets model info and optional default data into internal memory.
Internal components
• Power card assy.
• Logics card assy.
- Serviceable Inverter DSP (Logic) Card = Drive Board
- Differentiates
between Hydraulic
or Traction
DSP Card
- You can swap
inverters, but you
need to swap the
DSP card also.
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Power Supply
Logic Power Supply Card
16 pin
Logic Card
connector
Main harness side connectors are bundled together. 16 pin connector
Logic Card:
• Main Inputs and
Outputs
• Digital Signals
• CANBUS
• Serviceable
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Power Supply card:

• 5V References
• Circuit negatives
• Powers the DSP’s
• Serviceable
TruckTool
WWW.TRUCKTOOL-ONLINE.COM
TX-M Diagnostic Software

Downloading Procedure can be
found in Unicarriers University.
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5/15/2019
TruckTool
QUESTIONS?
29

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5/15/2019

TXM Introductory Service Training

TXM Introductory Service Training

Instructor for this class is:

Your name here

3 Wheel Electric Counterbalance

TXM Model – Produced in Houston, Texas by MCFA

3 Wheel Electric Counterbalance

What's new for UniCarriers?

What's new for UniCarriers?

Operator Presence System

PDS = 4 Wheel Models

Controlled Cornering Speed

Removable, locking, spring-loaded Tow Pin

Hydraulic Tank Detail

This motor has

Drive Motors & transfer cases

• Magnetic type automatic

• Encoder bearings in each

Manual release of Park Brake

(1) Loosen the brake

This emergency brake release tri-angle

This tri-angle is NOT easy to install to

Park Brake Misuse

BEWARE: The left side brake is installed under a

NOTE: There are two part-numbers for the

Park Brake Misuse

New condition Burnt condition

• Oil immersed Wet Disc Brakes

•Left side shown

•Brake Cylinder Brake Push Pin

Beware, the O-ring is positioned off-center

Max turns from lock-

Steering System (Horn locations)

STD: the grab handle on the right-hand rear over-

Steering System (EPS)

Steering System (EPS)

No need to grease before 3-wheel configuration

Be aware of the “D”

2. Make sure the wheels are visually in the center position.

3. NOTE: “D” shaped shaft of steer angle sensor.

Here’s the drain plug.

This is an end-cap for the

Electronic Steering System (EPS)

What does it do?

Steering System (EPS)

Steering System (EPS)

Contactors and Fuses

(1) 500 A Line fuse

(4) 10 A Key fuse

Controllers, Logics and Inverters

L&R Traction Inverters

Meter panel Assembly

Controllers, Logics and Inverters

Modules mount directly to the Counterweight

Controllers, Logics and Inverters

Use Dielectric grease

Controllers, Logics and Inverters

Controllers, Logics and Inverters

L Traction Inverter R Traction Inverter Pump inverter