Electrical System – 5000

General
Valid from serial number T-code
709569- 483,484,657,658,793,794
Order number Date
217166-040 2004-09-20

1- Electrical System – 5000

1.1 General
1.1.1 Electrical Panel

1.2 Symbol List and Electrical Diagrams

1.2.1 Symbol List
Symbol Description Symbol Description
Battery

Brake coil, normally released Brake coil, normally applied

Switch, normally open Switch, normally closed

Push-button switch, normally Push-button switch, normally

open closed

© BT Europe AB Service Manual REFLEX RR M12, M14, M16Approved by: K-G Andersson 1- 1
 Electrical System – 5000
Symbol List and Electrical Diagrams
T-code Valid from serial number
483,484,657,658,793,794 709569-
Date Order number
2004-09-20 217166-040

Symbol Description Symbol Description

Momentary switch, normally Momentary switch, normally
open closed

Latching, push-button switch, Emergency switch

normally open

Key switch, normally open Push-button switch, latching

and momentary

Electro-magnetic switch, nor- Electro-magnetic switch, nor-

mally open mally closed

Pressure-sensitive switch, Pressure-sensitive switch,

normally open normally closed

Capacitive switch, normally Capacitive switch, normally

open closed

Inductive sensor, normally Inductive sensor, normally

open closed

Pulse generator

Seat heater with thermostat Thermoelectric sensor

Motor, general Series motor, armature wind-

ing, DC

Series motor, DC Motor, permanent magnet

1- 2 © BT Europe AB Service Manual REFLEX RR M12, M14, M16Approved by: K-G Anders-
 Electrical System – 5000
Symbol List and Electrical Diagrams
Valid from serial number T-code
709569- 483,484,657,658,793,794
Order number Date
217166-040 2004-09-20

Symbol Description Symbol Description

Three-phase motor, AC

Series winding Shunt winding

Converter, AC/DC Converter, AC/DC

Variable resistor (potentiome- Resistor

ter)

Contactor Horn

Lamp Valve

Fuse Diode

Zener diode Light emitting diode (LED)

Contact Contact, multiple-poles

Capacitor Feed cable

© BT Europe AB Service Manual REFLEX RR M12, M14, M16Approved by: K-G Andersson 1- 3
1- 4
1 1

X1 G1 48 V X1 SHUNT WIRE
A Sh. 3 1 + - 40
Sh. 2

© BT Europe AB
ELECTRONIC CARD
MEASURING WIRES A5
Date
T-code

72
603 INP. BATT. INDI CURRENT -(+)
2004-09-20

71
602 INP. BATT. INDI -, CURRENT -(-)

70
601 INP. BATT. INDI +
MAIN CONTACTOR
K10
A1 A2 31
804 OUT. MAIN CONTACTOR
10A
483,484,657,658,793,794

F62
2 1 23
808 INP. MAIN CONTACTOR

Sh. 2 8

S1 X30
Sh. 2 22 3 4 34
101 INP. SETUP SELECT

S2 X30
Electrical System – 5000

3 4 35
102 INP. SETUP UP
Symbol List and Electrical Diagrams

S3 X30
709569-

3 4 36
103 INP. SETUP DOWN
1.2.2 Electrical diagram (1/10)
217166-040
Order number

GODKÄND/APPROVED ANMÄRKNING/REMARK
Valid from serial number

040115 SIA BENÄMNING/TITLE BLAD/SHEETREV REV

KRETSSCHEMA 1 10 PREL - PROD A

RITN NR/DRG. NO.

CIRCUIT DIAGRAM
ÄNDRING/REVISION ÄO NR/ENG CHG DATUM/DATE SIGN/BY D 216724

Service Manual REFLEX RR M12, M14, M16Approved by: K-G Anders-

© BT Europe AB
1 1

TRANSISTORPANEL, DRIVE
A1

125A
F1
Sh. 1 7 8
B + +
A
U 2
DRIVE MOTOR
Sh. 1 4 40 M1
B - U
V 3 V
THERMO ELECTRICAL SENSOR IN M1
X26
M
14 3~A
7
W
X26 B1
W 4
709569-

11
4

ELECTRONIC CARD
217166-040

10 A5
3
Order number

SPEED MEASURING IN M1
U11 117
X27 X27 12 401 OUT CAN +15VDC
R Bl 12
5
B
+
13 118
X27 X27 402 OUT CAN GND
Bk Wh 13
6
A
-
Valid from serial number

10 119
403 OUT/IN CAN H

X30
Sh. 1 3 22 11 120
1 404 OUT/IN CAN L

SERVICE KEY INTERFACE

X41
X45 X31
1 117
Electrical System – 5000

X45 X31
Symbol List and Electrical Diagrams

2 118

X45 X31
3 119 119
Sh. 7
X45 X31
1.2.3 Electrical diagram (2/10)

4 120 120
Sh. 7
Date

R100
T-code

2004-09-20

GODKÄND/APPROVED ANMÄRKNING/REMARK

Service Manual REFLEX RR M12, M14, M16Approved by: K-G Andersson

040115 SIA BENÄMNING/TITLE BLAD/SHEETREV REV

KRETSSCHEMA 2 10 PREL - PROD A

RITN NR/DRG. NO.

CIRCUIT DIAGRAM
ÄNDRING/REVISION ÄO NR/ENG CHG DATUM/DATE SIGN/BY D 216724
483,484,657,658,793,794

1- 5
1- 6
ELECTRONIC CARD
A5
7,5A
F60
A Sh. 1 4 1 21
805 +48VDC

X30
24

© BT Europe AB
807 INP. KEY

S23
Date

1 3 43
110 INP. LEFT FOOT SWITCH
T-code

KEY EMERGENCY SWITCH OFF

X30 S17 S21 X30
2004-09-20

15 61a 24 1 2 22
809 +48VDC SUPPLY OUTPUTS

Sh. 2 4 22
X32
45
104 INP. DRIVE, FORK DIRECTION, CREEP
S26
X32
3
X32
2
483,484,657,658,793,794

46
105 INP. DRIVE, STEER WHEEL DIR., CREEP
1

X18 S27 X18

1 3 47
106 INP. DRIVE, FORK DIRECTION

X18 S29 X18

1 3 48
107 INP. DRIVE, STEER WHEEL DIRECTION

X25 S89 X25

1 3 49
203 INP. SEAT SWITCH
Electrical System – 5000
Symbol List and Electrical Diagrams

709569-

1.2.4 Electrical diagram (3/10)

217166-040
Order number

GODKÄND/APPROVED ANMÄRKNING/REMARK
Valid from serial number

040115 SIA BENÄMNING/TITLE BLAD/SHEETREV REV

KRETSSCHEMA 3 10 PREL - PROD A

RITN NR/DRG. NO.

CIRCUIT DIAGRAM
ÄNDRING/REVISION ÄO NR/ENG CHG DATUM/DATE SIGN/BY D 216724

Service Manual REFLEX RR M12, M14, M16Approved by: K-G Anders-

 1 1

© BT Europe AB
ELECTRONIC CARD
A5

Sh. 6 27 27
507 POT FEED 7-7,5 VDC
A X19

1
X19
50
R1 501 INP. SPEED REFERENCE VALUE

2
X19
Sh. 6 28 28
508 POT 0V
S31
X30 X14 X16 X52 X52 X16 X14
Sh. 3 5 22 79
206 INP. SPEED REDUCTION
709569-

X22 S56 X22

217166-040

Br Bl 80
207 INP. REACH CARRIAGE, LOW SPEED IN
HORN
Order number

H1
X32 S18 X32 M12
3 4 54 R Bk Bl- +R 107
M 307 OUT. FAN POWER, ELECTRIC PANEL
Ye
Valid from serial number

SEAT HEATER
X25 E10 X25

FAN PUMPMOTOR
M10
X35 X35
+ M
-

Sh. 2 5 40
Electrical System – 5000
Symbol List and Electrical Diagrams

EXTERNAL EQUIPMENT WORKING LIGHT

10A X42 X42
F63 X30 S99 E4 E3
Sh. 3 5 1 26 1 1 26 1 5 191 192
1.2.5 Electrical diagram (4/10)
Date

X30
40 2 2 40
T-code

2004-09-20

GODKÄND/APPROVED ANMÄRKNING/REMARK

Service Manual REFLEX RR M12, M14, M16Approved by: K-G Andersson

040115 SIA BENÄMNING/TITLE BLAD/SHEETREV REV

KRETSSCHEMA 4 10 PREL - PROD A

RITN NR/DRG. NO.

CIRCUIT DIAGRAM
ÄNDRING/REVISION ÄO NR/ENG CHG DATUM/DATE SIGN/BY D 216724
483,484,657,658,793,794

1- 7
1- 8
1 1

ELECTRONIC CARD
A5

A Sh. 10 29 29
810 +15VDC

Sh. 10 30 30
811 0VDC

© BT Europe AB
S66
X21 X21
Br Bk 58
210
Date

INP. STEER WHEEL ANGLE A

Wh
T-code

Bl
X21 X21
59
211 INP. STEER WHEEL ANGLE B
2004-09-20

S65
X30 X20 X20
Sh. 4 6 22 Br Bk 57 INP. STEER WHEEL
209
REFERENCE 180 DEG.
X20

Bl
806

Sh. 4 6 40 40
902 0VDC
483,484,657,658,793,794

30A
Sh. 4 1 F61 25
901 +48VDC STEER SERVO

M6
X24
Bk R 60
M 903 OUT. + STEER MOTOR

X24
61
904 OUT. - STEER MOTOR

U1
Electrical System – 5000

X32
Bk R 62
Symbol List and Electrical Diagrams

M 509 INP. STEERING WHEEL TACHO +

709569-

X34
129
511 0VDC FOR TACHO
1.2.6 Electrical diagram (5/10)
217166-040
Order number

GODKÄND/APPROVED ANMÄRKNING/REMARK

040115 SIA
Valid from serial number

BENÄMNING/TITLE BLAD/SHEETREV REV

KRETSSCHEMA 5 10 PREL - PROD A

RITN NR/DRG. NO.

CIRCUIT DIAGRAM
ÄNDRING/REVISION ÄO NR/ENG CHG DATUM/DATE SIGN/BY D 216724

Service Manual REFLEX RR M12, M14, M16Approved by: K-G Anders-

 1 1

© BT Europe AB
EMERGENCY MODE
X30 S131
A Sh. 5 7 22 1 2
ELECTRONIC CARD
A5

X37 Y1 X37
Sh. 5 7 40 64
802 OUT. PARKING BRAKE

DISPLAY
A6
709569-

X31
SERIE + 1 121
405 SERIE +
217166-040

X31
2 122
Order number

SERIE - 406 SERIE -

RS 485
X31
RX + 3 125
407 TX+

X31
RX - 4 126
408 TX-
Valid from serial number

Sh. 4 8 27
X36

1
X36
51
R2 502 INP. BRAKE REFERENCE VALUE

2
X36
Sh. 4 8 28
Electrical System – 5000
Symbol List and Electrical Diagrams

125
Sh. 10
1.2.7 Electrical diagram (6/10)

126
Sh. 10
Date
T-code

2004-09-20

GODKÄND/APPROVED ANMÄRKNING/REMARK

Service Manual REFLEX RR M12, M14, M16Approved by: K-G Andersson

040115 SIA BENÄMNING/TITLE BLAD/SHEETREV REV

KRETSSCHEMA 6 10 PREL - PROD A

RR/M RITN NR/DRG. NO.

CIRCUIT DIAGRAM
ÄNDRING/REVISION ÄO NR/ENG CHG DATUM/DATE SIGN/BY RR/M D 216724
483,484,657,658,793,794

1- 9
1- 10

1 1
© BT Europe AB

1.2.8 Electrical diagram (7/10)

2004-09-20
Date
483,484,657,658,793,794
T-code
Symbol List and Electrical Diagrams
Electrical System – 5000
Service Manual REFLEX RR M12, M14, M16Approved by: K-G Anders-

TRANSITOR REGULATOR, LIFT

A2
160A
F3
Sh. 2 8 5 48VDC J2-1 119 119
B+ OUT/IN: CAN H. Sh. 2
PWR. SUPPLY

Sh. 6 8 40 40 J2-8 120 120

B- GROUND OUT/IN CAN L Sh. 2

PUMP MOTOR
D1 A2/E2 6
M3 M OUT. PUMP MOTOR

E1 22 22
INP: 48VDC, KEY SWITCH J2-16 Sh. 6 8

Order number

Valid from serial number

217166-040

709569-
GODKÄND/APPROVED ANMÄRKNING/REMARK

040115 SIA BENÄMNING/TITLE BLAD/SHEETREV REV

KRETSSCHEMA 7 10 PREL - PROD A

RITN NR/DRG. NO.

ÄNDRING/REVISION ÄO NR/ENG CHG DATUM/DATE SIGN/BY

CIRCUIT DIAGRAM
D 216724
© BT Europe AB

1 1

ELECTRONIC CARD
X32 X11
Sh. 6 27 A5
Service Manual REFLEX RR M12, M14, M16Approved by: K-G Andersson

Ye
X11 X33
A 82
R11 503 INP. JOYSTICK FORK

R
X32 X11

Gr
Sh. 6 28

Ye

1.2.9 Electrical diagram (8/10)

217166-040
Order number
709569-
Valid from serial number
Symbol List and Electrical Diagrams
Electrical System – 5000
X11 X33
83
R12 504 INP. JOYSTICK REACH CARRIAGE

R
Gr
Ye
X11 X33
84
R13 R 505 INP. JOYSTICK TILT
Gr
Ye

X11 X33
85
R14 506 INP. JOYSTICK SPARE 1
R
Gr
Ye

X11 X33
86
R15 510 INP. JOYSTICK SPARE 2
R
Gr

X30 X32 S33 X33

Sh. 7 9 22 5 1 100
205 INP. OVERRIDE

202 OUT. DATA COLLECT, LIFT

208 OUT. DATA COLLECT, DRIVE

S32
X15 X16 X16 X15

483,484,657,658,793,794
2004-09-20
Date

T-code
Sh. 7 9 40 98
301 INP. LIFT LIMIT SPECIAL HEIGHT

GODKÄND/APPROVED ANMÄRKNING/REMARK

040115 SIA BENÄMNING/TITLE BLAD/SHEETREV REV

KRETSSCHEMA 8 10 PREL - PROD A

RITN NR/DRG. NO.

ÄNDRING/REVISION ÄO NR/ENG CHG DATUM/DATE SIGN/BY

CIRCUIT DIAGRAM
D 216724
1- 11
1- 12

1 1
© BT Europe AB

EMERGENCY MODE
100 / 25W
X30 S132 R102
Sh. 8 10 22 1 2 ELECTRONIC CARD
A5

X14 X17 Y10 X17 X14

A Sh. 8 10 40 Bk 1 3Wh 88
803 OUT. FORK LOWER

X17 X14
Bk 1 2Gr 89
701 OUT. FORK LIFT

1.2.10 Electrical diagram (9/10)

2004-09-20
Date
483,484,657,658,793,794
T-code
Symbol List and Electrical Diagrams
Electrical System – 5000
EMERGENCY MODE
S133
Service Manual REFLEX RR M12, M14, M16Approved by: K-G Anders-

1 2

Y12 X17 X14

Bk 1 2R 90
702 OUT. REACH CARRIAGE, IN

Y13 X17 X14

Bk 1 2Bl 91
703 OUT REACH CARRIAGE, OUT

Y14 X17 X14

Bk 1 2Or 92
704 OUT. TILT DOWN

Y15 X17 X15

Bk 1 2Ye 93
705 OUT. TILT UP

X29 X50 Y16 X50 X29 X17 X15

1 2 94
706 OUT. SPARE 1A

Y17 X50 X29 X17 X15

1 2 95
707 OUT. SPARE 1B

Y18 X16 X15

Order number

Valid from serial number

217166-040

709569-
2 1 96
708 OUT. SPARE 2A

Y19 X16 X15

2 1 97
709 OUT. SPARE 2B

GODKÄND/APPROVED ANMÄRKNING/REMARK

040115 SIA BENÄMNING/TITLE BLAD/SHEETREV REV

KRETSSCHEMA 9 10 PREL - PROD A

RITN NR/DRG. NO.

ÄNDRING/REVISION ÄO NR/ENG CHG DATUM/DATE SIGN/BY

CIRCUIT DIAGRAM
D 216724
© BT Europe AB

1 1

LIFT HEIGHT INDICATOR

A8
X30 X45X8 X8 X45 X31
Sh. 9 22
Service Manual REFLEX RR M12, M14, M16Approved by: K-G Andersson

3 +48V RX+ 5

A X8 X45 X31
RX- 2 125
4 0V Sh. 6

126

1.2.11 Electrical diagram (10/10)

217166-040
Order number
709569-
Valid from serial number
Symbol List and Electrical Diagrams
Electrical System – 5000
Sh. 6
X8
X45
X30

ELECTRONIC CARD
PRE SELECTION HEIGHT UNIT A5
A7
X32 X33
Sh. 9 40 RX+ 7 125
6 0V 407 TX+

X32 X34
RX- 3 126
4 +48V 408 TX-

RS 485
X34
TX+ 1 127
409 RX+ HEIGHT UNIT

X34
TX- 5 128
410 RX- HEIGHT UNIT

U10
X14 X16 X28 X28 X16 X15
Sh. 5 29 R Wh 98
INP. HEIGHT COUNTER A
+
301
A

X14 X16 X28 X28 X16 X15

Sh. 5 30 Bk Bl 99
INP. HEIGHT COUNTER B
-
302
B
MAST, UPPER POS.

X14 X16 S45 X16 X15

21 22 106
303 INP. HEIGHT REFERENCE

483,484,657,658,793,794
2004-09-20
Date

T-code
MAST, LOWER POS.
X43 S46 X43
Br Bl

GODKÄND/APPROVED ANMÄRKNING/REMARK

040115 SIA BENÄMNING/TITLE BLAD/SHEETREV REV

KRETSSCHEMA 10 10 PREL - PROD A

RITN NR/DRG. NO.

ÄNDRING/REVISION ÄO NR/ENG CHG DATUM/DATE SIGN/BY

CIRCUIT DIAGRAM
D 216724
1- 13
 Electrical System – 5000
Symbol List and Electrical Diagrams
T-code Valid from serial number
483,484,657,658,793,794 709569-
Date Order number
2004-09-20 217166-040

1.2.12 Component List

Symbol Designation/function Picture

A1 Frequency converter, M1 5
A2 Frequency converter, M3 5
A5 Electronic card 5
A6 Display 1
A7 Preset height
A8 Height indication display

B1 Thermoelectric sensor, M1 5

E10 Seat heater 4

E3, E4 Work spotlight 7

F1 Drive motor fuse, 125 A 5

F3 Pump motor fuse 160 A 5
F60 Operating fuse for A5 card, 7,5 A 5
F61 Steering motor fuse, 30 A 5
F62 Operating fuse for K10, 10 A 5
F63 Operating fuse for extra equipment, 10/16 A 5

G1 Battery, 48 V 8

H1 Horn 5

K10 Main contactor 5

M1 Drive motor 5
M3 Pump motor 5
M6 Steering motor 5
M10 Fan for pump motor 5
M12 Fan for electrical panel 5

1- 14 © BT Europe AB Service Manual REFLEX RR M12, M14, M16Approved by: K-G Anders-
 Electrical System – 5000
Symbol List and Electrical Diagrams
Valid from serial number T-code
709569- 483,484,657,658,793,794
Order number Date
217166-040 2004-09-20

Symbol Designation/function Picture

R1 Potentiometer, driving 5
R2 Potentiometer, braking 5
R11 Potentiometer, forks raised/lowered 2
R12 Potentiometer, reach carriage 2
R13 Potentiometer, tilt 2
R14 Potentiometer, extra hydraulic function 2
R15 Potentiometer, extra hydraulic function 2
R100 Resistor, service key 8
R102 Resistor, emergency lowered forks 5

S1 Microswitch, driver number/programming 1

S2 Microswitch, driver number/step up 1
S3 Microswitch, driver number/step down 1
S17 Key switch 1
S18 Microswitch, horn 2
S21 Emergency switch 1
S23 Safety switch, left foot-pedal 3
S26 Microswitch, direction of travel selector at 2
crawl speed
S27 Microswitch travel direction (foot), direc- 3
tion of forks
S29 Microswitch travel direction (foot), direc- 3
tion of steering wheel
S31 Microswitch, speed reduction 8
S32 Microswitch, max. lift height 8
S33 Microswitch, by-pass max. lift height 1
S45 Microswitch, height indicator 7
S46 Magnetic switch, lowering between free lift 7
and main lift
S56 Magnetic switch, retracting mast low
speed

© BT Europe AB Service Manual REFLEX RR M12, M14, M16Approved by: K-G Andersson 1- 15
 Electrical System – 5000
Symbol List and Electrical Diagrams
T-code Valid from serial number
483,484,657,658,793,794 709569-
Date Order number
2004-09-20 217166-040

Symbol Designation/function Picture

S65 Pulse sensor, steering wheel centre 5
S66 Pulse sensor, steering wheel direction 5
S89 Microswitch, seat 4
S99 Microswitch, work spotlight 1
S131 Microswitch, released parking brakes 5
S132 Microswitch, emergency lowered forks 5
S133 Microswitch, emergency retraction of mast 5

U1 Tachometer, steering 2
U10 Pulse sensor, height meter 7
U11 Pulse sensor, drive motor 5

X1 Contact 8
X8 Contact 8
X11 Contact 2
X14 Contact 5
X15 Contact 5
X16 Contact 6
X17 Contact 6
X18 Contact 5
X19 Contact 5
X20 Contact 5
X21 Contact 5
X24 Contact 5
X25 Contact 4
X26 Contact 5
X27 Contact 5
X28 Contact 7
X29 Contact 6
X30 Contact 5
X31 Contact 5

1- 16 © BT Europe AB Service Manual REFLEX RR M12, M14, M16Approved by: K-G Anders-
 Electrical System – 5000
Symbol List and Electrical Diagrams
Valid from serial number T-code
709569- 483,484,657,658,793,794
Order number Date
217166-040 2004-09-20

Symbol Designation/function Picture

X32 Contact 5
X33 Contact 5
X34 Contact 5
X35 Contact 5
X36 Contact 5
X37 Contact 5
X41 Contact 7
X42 Contact 5
X43 Contact 6
X45 Contact 1
X50 Contact 8
X52 Contact 6

Y1 Magnet, parking brakes 5

Y10 Solenoid valve, lift/lower 6
Y12 Solenoid valve, reach carriage in 6
Y13 Solenoid valve, reach carriage out 6
Y14 Solenoid valve, tilt down 6
Y15 Solenoid valve, tilt up 6
Y16 Solenoid valve, extra hydraulic function 1A 6
Y17 Solenoid valve, extra hydraulic function 1B 6
Y18 Solenoid valve, extra hydraulic function 2A 6
Y19 Solenoid valve, extra hydraulic function 2B 6

© BT Europe AB Service Manual REFLEX RR M12, M14, M16Approved by: K-G Andersson 1- 17