Electrical diagram

Components
Order number Date Valid from serial number T-code
7503877-040 2009-01-09 6070557- 815, 816

20 – Electrical diagram

20.1 Components
Designation Function Component type Other
A1 Central Information Display PCB with display
(CID)
A2 Power steering (EPS) Electronic card
A5 Main microcontroller (MCU) PCB
A6 Sensor control PCB
A7* Cabin heating control PCB
A9 Power distribution Fuse box
A11* Stereo/CD Stereo/CD
A82 Data management unit PCB T.W.I.S. unit in the truck
B1 Temperature sensor in [M1] Temperature sensor
B2 Temperature sensor in [M3] Temperature sensor
B4 Hydraulic lift pressure Pressure sensor
B5* Fork tilt angle Angle sensor
B11 Speed measurement [M1] Pulse transducer
B12 Speed measurement [M3] Pulse transducer
B13 Pulse transducer, steering Twin sensor bearing
wheel
B17 Reference for 180° steering Inductive sensor
angle
B18 Height sensor free lift Sensor
B19 Height sensor main lift Sensor
B20 Raise/lower forks Hall sensor Nominal output voltage:
B21 Fork carriage in/out Hall sensor 0,5 V (min.)
2,5 V (neutral position)
B22 Fork tilt up/down Hall sensor 4,5 V (max.)
B23* Sideshift right/left Hall sensor
B24* Forkspread/aux Hall sensor
B25 Height reference, forks near Inductive sensor
top of mast

© BT Repair Manual RRE140/160/180/200/250 20 – 1

 Electrical diagram
Components
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-01-09 7503877-040

Designation Function Component type Other

B26 Position for reach carriage, Inductive sensor Distance: 0-6,5 mm
sensor 1
B27 Position for reach carriage, Inductive sensor
sensor 2
B28* Cabin tilt in lowest position Inductive sensor
B29* Cabin tilt in highest position Inductive sensor
B30 Battery in original position Inductive sensor
B31 Safety pedal Inductive sensor
B32 Pedals (acceleration and Hall sensor Nominal output voltage:
brake) 0,5 V (min.)
4,5 V (max.)
B33 Height reference, mast near Inductive sensor
bottom position
B35 Horn Horn
B36 Travel direction selector Hall sensor
B38* Height preselector, next level Hall sensor
B39* Height limitation override Hall sensor
B40* Forks to horizontal position Hall sensor
B41* Sideshift to centre position Hall sensor
B42* Change of function for fifth Hall sensor
mini lever
B43* Cabin tilt activation Hall sensor
B44* Activation of extra function 1 Hall sensor
B45* Activation of extra function 2 Hall sensor
B46 Height reference mast lower- Inductive sensor Distance: 0-6,5 mm
ing
B47* Sideshift sensor left-hand Magnetic sensor
side
B48* Sideshift sensor right-hand Magnetic sensor
side
B49 Seat switch Inductive sensor Distance: 0-6,5 mm
B50* Fork camera Camera

20 – 2 Repair Manual RRE140/160/180/200/250 © BT

 Electrical diagram
Components
Order number Date Valid from serial number T-code
7503877-040 2009-01-09 6070557- 815, 816

Designation Function Component type Other

B57 Height reference, mast low- Inductive sensor
ering
B58 Height reference, forks Inductive sensor
below 1 m
B90 Height reference, mast low- Inductive sensor
ering
E3* Working light Lamp
E4* Working light Lamp
E5* Working light Lamp
E6* Working light Lamp
E10* Seat heater Resistor
F1 Fuse for [T1] Fuse 160 A/200 A
F3 Fuse for [T2] Fuse 250 A/325 A
F60 Fuse for relays Fuse 3 A
F61 Main fuse for [A5] Fuse 7,5 A
F62 Main fuse for [A1] Fuse 3 A
F63 Fuse for [P6] Fuse 3 A
F64 Fuse for activation of [A2] Fuse 3 A
F65* General Function Unit fuse Fuse 5 A
F66* Fuse for [T5] and [T6] Fuse 7,5 A
F69 Fuse for [X42] and [S133] Fuse 10 A
F71 Fuse for [A5] Fuse 7,5 A
F72 Fuse for [A2] Fuse 30 A
F73 Fuse for control voltage Fuse 7,5 A
F74 Fuse for [A1] and [A5] Fuse 3 A
F75* Fuse for working light Fuse 10 A
F76* Fuse for [T3] Fuse 7,5 A
F77* Fuse for seat heater Fuse 10 A
F90* Fuse for cabin heating Fuse 100 A (cold store cabin)
F91* Control circuitry fuse for Fuse 7,5 A (cold store cabin)
heater
F92* Fuse for heater element Fuse 25 A (cold store cabin)
F93* Fuse for heater element Fuse 25 A (cold store cabin)
F94* Fuse for heater element Fuse 25 A (cold store cabin)
F95* Fuse for heater element Fuse 25 A (cold store cabin)
G1 Truck battery Battery 48 V
G3 Cooling of [T1] and [T2] Fan motor

© BT Repair Manual RRE140/160/180/200/250 20 – 3

 Electrical diagram
Components
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-01-09 7503877-040

Designation Function Component type Other

G4 Cooling of [M3] Fan motor
G5* Fan for ventilation Fan motor (cold store cabin)
K1 Electronic ignition key PCB
K20 Key relay Power relay 460–330 ohms at
48 V DC
M1 Drive motor 3 phase AC motor
M3 Pump motor 3 phase AC motor
M6 Steering servo motor Stepper motor
P4 Horn Horn
P5* Warning lamp LEDs Flashing: ~2 Hz
Nominal current: 70 mA
P6* Load Information Display PCB with display
(LID)
P7* Vehicle alarm Horn
P10* Loud speaker Loud speaker
P11* Loud speaker Loud speaker
P12* Vehicle alarm Lamp
P13* Vehicle alarm Lamp
P14* TV monitor Monitor
Q1 Parking brake Electromagnetic brake 32 ohms
Q2 Valve for main mast lift Electromagnetic valve 22 ohms
Q3 Valve for initial mast lift Electromagnetic valve
Q4 Valve for main mast lowering Electromagnetic valve
Q5 Valve for initial mast lower- Electromagnetic valve
ing
Q6 Valve for reach carriage in Electromagnetic valve 25 ohms
Q7 Valve for reach carriage out Electromagnetic valve
Q8 Valve for extra hydraulic Electromagnetic valve 25 ohms
function, direction A
Q9 Valve for extra hydraulic Electromagnetic valve
function, direction B
Q10 Main relay Contacts 150 ohms
Q11 Valve for cabin tilt upwards Electromagnetic valve 25 ohms
Q12 Valve for extra hydraulic Electromagnetic valve
function 2
Q14 Valve for extra hydraulic Electromagnetic valve
function 3
Q15 Valve for extra hydraulic Electromagnetic valve
function 4

20 – 4 Repair Manual RRE140/160/180/200/250 © BT

 Electrical diagram
Components
Order number Date Valid from serial number T-code
7503877-040 2009-01-09 6070557- 815, 816

Designation Function Component type Other

Q16* Support arm brake (left) Electromagnetic brake
Q17* Support arm brake (right) Electromagnetic brake
Q18 Valve for fork tilt/sideshift Electromagnetic valve
Q19 Valve for fork tilt/sideshift Electromagnetic valve
Q21 Valve for cabin tilt down- Electromagnetic valve
wards
Q30* Relay for cabin heating Power relay
Q31* Relay for initial heating Power relay
Q32* Relay for defroster Power relay
R1* Heater element Heater element 4x400 W
R2* Heater element Heater element 4x400 W
R3* Speed control Resistor
R4* Speed control Resistor
R5* Temperature control Potentiometer
R5* Temperature control Potentiometer
R10* Damping resistance Resistor 680 ohms
R102 Damping resistance for Resistor 120 ohms
CAN1
R202 Damping resistance for Resistor 120 ohms
CAN2
S21 Emergency switch Switch Normally closed
S96* Changeover switch, heater Rotary switch
fan
S99* Working light off/on Push button
S126* Seat heater off/on Push button
S133 Release of parking brake Switch
S181* Power switch, heater coils Power switch
T1 Control of drive motor [M1] Frequency converter DC to 3 phase AC
T2 Control of pump motor [M3] Frequency converter DC to 3 phase AC
T3* Voltage converter DC/DC converter From +48 V DC to
+12 V DC
T4* Antenna Antenna
T5* Voltage converter DC/DC converter From +48 V DC to
+12 V DC
T6* Voltage converter DC/DC converter From +48 VDC to
+24 V DC
T20* Antenna Antenna T.W.I.S.
X1* Connection for battery Contact (battery cut out
connector)

© BT Repair Manual RRE140/160/180/200/250 20 – 5

 Electrical diagram
Components
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-01-09 7503877-040

Designation Function Component type Other

X3 Connection for battery Contact (battery cut out
connector)
X26* Connection for General Contact
Function Unit (GFU)
X41 Connection for service key CAN contact
X42 Socket 48 V DC Contact
X43* Socket 12 V DC Contact
X44* Socket 24 V DC Contact

* option

20 – 6 Repair Manual RRE140/160/180/200/250 © BT

 Electrical diagram
Cable connections and pole bolts
Order number Date Valid from serial number T-code
7503877-040 2009-01-09 6070557- 815, 816

20.2 Cable connections and pole bolts

20.2.1 ACT/ACH regulators

Connections, travel control (ACT)
Connection Cable Designation Active In/Out
1 14 Motor temperature In
2 35 Cabin tilt, down 0 V PWM Out
3 -
4 -
5 -
6 11 GND 0V Out
7 218 CAN2 - GND 0V In
8 219 CAN2 H 0–5 V In/Out
9 27 Off/On 48 V In
10 34 Cabin tilt, up 0 V PWM Out
11 10 Sensor + 12 V, 50 mA Out
12 -
13 12 Pulse transducer, 12 V, 1 kOhm In
phase 1
14 13 Pulse transducer, 12 V, 1 kOhm In
phase 2
15 –
16 220 CAN2 L 0–5 V In/Out
B+ 8 Battery + 48 V In
B- 40 Battery - 0V In
U 2 Motor winding U 0–33 V Out
V 3 Motor winding V 0–33 V Out
W 4 Motor winding W 0–33 V Out

© BT Repair Manual RRE140/160/180/200/250 20 – 7

 Electrical diagram
Cable connections and pole bolts
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-01-09 7503877-040

Connections, lift regulator (ACH)

Connection Cable Designation Active In/Out
1 19 Motor temperature In
2 35 Valve, lower initial 0 V PWM Out
mast
3 -
4 -
5 -
6 16 GND 0V Out
7 218 CAN2 – 0V In
8 219 CAN2 H 0–5 V In/Out
9 27 Off/On 48 V In
10 36 Valve, lift initial mast 0 V PWM Out
11 15 Sensor + 12 V, 50 mA Out
12 16 Choice of ID 0V In
13 17 Pulse transducer, 12 V, 1 kOhm In
phase 1
14 18 Pulse transducer, 12 V, 1 kOhm In
phase 2
15 219 CAN2 H 0–5 V In/Out
16 220 CAN L 0–5 V In/Out
B+ 8 Battery + 48 V In
B- 40 Battery – 0V In
U 5 Motor winding U 0–33 V Out
V 6 Motor winding V 0–33 V Out
W 7 Motor winding W 0–33 V Out

20 – 8 Repair Manual RRE140/160/180/200/250 © BT

 Electrical diagram
Cable connections and pole bolts
Order number Date Valid from serial number T-code
7503877-040 2009-01-09 6070557- 815, 816

20.2.2 Connections to CID

Connections, CID
Connection Cables Designation Active In/
Out
X503:1 39 +5 VDC for sensor +5 VDC, ±2 % Out
X503:2 101 Height preselector, next level <1.6 V/>3.5 V In
X503:3 103 Fork tilt to horizontal position <1.6 V/>3.5 V In
X503:4 105 Extra function for joystick #5 <1.6 V/>3.5 V In
X503:5 107 Extra function #1 <1.6 V/>3.5 V In
X503:6 –
X503:7 49 Analogue minus +0 VDC Out
X503:8 102 Height pre-set – pressurised <1.6 V/>3.5 V In
X503:9 104 Sideshift to middle position <1.6 V/>3.5 V In
X503:10 106 Cabin tilt <1.6 V/>3.5 V In
X503:11 108 Extra function #2 <1.6 V/>3.5 V In
X503:12 –
X504:1 Flashers, right In
X504:2 48 Steering pulse transducer 2B Pulse train In
X504:3 40 B- 0V In
X504:4 44 Steering pulse transducer 1B Pulse train In
X504:5 45 Minus for Steering pulse transducer 1 & 2 0V Out
X504:6 120 CAN1 low 0,5–2,5 V In/Out
X504:7 28 Key relay – status 48 VDC In
X504:8 120 CAN1 low 0,5–2,5 V In/Out
X504:9 119 CAN1 high 4,5–2,5 V In/Out
X504:10 Flashers, left In
X504:11 47 Steering pulse transducer 2A Pulse train In
X504:12 46 +5 VDC for steering pulse transducer 2 +5 VDC, ±2 % Out
X504:13 43 Steering pulse transducer 1A Pulse train In
X504:14 42 +5 VDC for steering pulse transducer 1 +5 VDC, ±2 % Out
X504:15 119 CAN1 high 4,5–2,5 V In/Out
X504:16 21 Emergency stop (ESO) 48 VDC In
X504:17 32 Key relay out 48 VDC Out
X504:18 24 +48 VDC 48 VDC In
X505:1 39 +5 VDC for sensor +5 VDC, ±2 % Out
X505:2 50 Joystick for Lift/Lowering 0,3 – 4.7 V In
X505:3 53 Joystick for AUX1/Fork Sideshift 0,3 – 4.7 V In

© BT Repair Manual RRE140/160/180/200/250 20 – 9

 Electrical diagram
Cable connections and pole bolts
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-01-09 7503877-040

Connections, CID
Connection Cables Designation Active In/
Out
X505:4 94 Travel direction selector 0,3 – 4.7 V In
X505:5 93 Horn <1.6 V/>3.5 V In
X505:6 –
X505:10 49 Analogue minus 0V Out
X505:11 51 Joystick for Reach Movement 0,3 – 4.7 V In
X505:12 54 Joystick for AUX2/Fork spread 0,3 – 4.7 V In
X505:14 <TBD>
X505:15 –
X505:17 52 Joystick for Fork tilting 0,3 – 4.7 V In
X506:1 132 +5 VDC for electronic start key +5 VDC, ±2 % Out
X506:2 133 Minus for electronic start key 0V Out
X506:3 134 Activation of electronic start key Out
X506:4 135 Clock for serial interface (SPI) Pulse train Out
X506:5 136 Data master in (SPI) Pulse train In
X506:6 137 Data master out (SPI) Pulse train Out

20.2.3 Connections to MCU

There are two 42-pin closed JPT contacts on the same side of the
board.

Connections, MCU
Connection Cables Designation Active In/
Out
X130:1 55 Current source +5 V 5V Out
X130:3 69 Lift pressure 0,5–4,5 V In
X130:4 85 Brake pedal, reference 1 (min.–max.) 0,5–4,5 V In
X130:5 70 Voltage measurement, battery 48 V In
X130:6 90 Earth, analogue 0V
X130:8 220 CAN2 low 0,5–2,5 V In/Out
X130:10 81 Cabin tilt in upright position 48 V In
X130:11 79 Reach carriage, sensor 2 48 V In
X130:12 75 Height sensor - forks, upper free lift, pulse A a
) 48 V In
X130:13 131 Height sensor - forks, upper free lift, pulse B 48 V In
X130:16 74 Fork tilt angle 0,5–4,5 V In
X130:17 87 Accelerator 0,5–4,5 V In

20 – 10 Repair Manual RRE140/160/180/200/250 © BT

 Electrical diagram
Cable connections and pole bolts
Order number Date Valid from serial number T-code
7503877-040 2009-01-09 6070557- 815, 816

Connections, MCU
Connection Cables Designation Active In/
Out
X130:18 86 Brake pedal, reference 2 (min.–max.) 4,5–0,5 V In
X130:19 71 Battery measurement 2 0V In
X130:20 30 Earth, digital 0V Out
X130:22 219 CAN2 high 4,5–2,5 V In/Out
X130:23 117 Current measurement +15 V, service key 15 V Out
X130:24 80 Cabin tilt in lowered position 48 V In
X130:25 57 Steered wheel 180° 48 V In
X130:26 76 Height sensor - forks, upper free lift, pulse B 48 V In
X130:27 139 Height reference - forks below free lift 48 V In
X130:29 56 Earth, analogue 0V
X130:30 125 Input signal, pressure sensor, mast
X130:31 84 Safety pedal 48 V In
X130:32 72 Battery measurement 1 0V In
X130:33 218 CAN2 earth 0V Out
X130:34 118 Earth, service key 0V
X130:37 29 Current source +15 V 15 V Out
X130:38 78 Reach carriage - sensor 1 48 V In
X130:39 73 Height reference - forks below free lift 48 V In
X130:40 130 Height sensor - forks, upper free lift, pulse A 48 V In
X130:41 83 Seat switch 48 V In
X131:1 22 Current source 48 V In
X131:2 141 Height reference – forks b) 48 V In
X131:4 Option: Speed limitation 3 In
X131:5 21 Status, emergency switch off In
X131:6 28 Status, key relay 48 V In
X131:7 31 Main relay 48 V Out
X131:8 121 Turn signal lights, left 48 V Out
X131:9 33 Fan control 0–48 V Out
X131:10 67 Valve for AUX. 3 0–48 V Out
X131:11 63 Valve for fork tilt/fork reach/AUX. 0–48 V Out
X131:12 97 Brake, right-hand support arm 0–48 V PWM Out
X131:13 60 Valve for reach carriage 0–24 V PWM Out
X131:14 40 Earth 0V
X131:15 23 Charging capacitor 48 V In/Out

© BT Repair Manual RRE140/160/180/200/250 20 – 11

 Electrical diagram
Cable connections and pole bolts
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-01-09 7503877-040

Connections, MCU
Connection Cables Designation Active In/
Out
X131:17 Option: Speed limitation 1 In
X131:18 111 Fork reach sensor, left-hand side 48 V In
X131:19 124 Login, special 48 V In
X131:20 95 Parking brake 48 V Out
X131:21 65 Valve for forkspread/AUX. 2 0–48 V Out
X131:24 68 Valve for AUX. 4 0–48 V Out
X131:25 88 Horn 48 V Out
X131:26 59 Valve for main mast lift 0-24 V PWM Out
X131:27 119 CAN1 high 4,5-2,5 V In/Out
X131:31 Option: Speed limitation 2 In
X131:32 112 Fork reach sensor, right-hand side 112 In
X131:34 34 Fan, chassis 0–48 V Out
X131:35 122 Turn signal lights, right 48 V Out
X131:36 98 Warning lamp 48 V Out
X131:37 62 Valve for reach carriage 0–48 V Out
X131:38 66 Valve for fork tilt/fork reach/AUX. 1 0–48 V Out
X131:39 96 Brake, left-hand support arm 0–48 V PWM Out
X131:40 58 Valve for main mast lowering 0–24 V PWM Out
X131:41 61 Reach valve 0–24 V PWM Out
X131:42 120 CAN1 low 0,5–2,5 V In/Out
a."Mast near to lowered position" when height measurement is not used.
b."Forks near top of mast" when height measurement is not used.

20 – 12 Repair Manual RRE140/160/180/200/250 © BT

 Electrical diagram
Fuse box A9
Order number Date Valid from serial number T-code
7503877-040 2009-01-09 6070557- 815, 816

20.3 Fuse box A9

F73 F75 F77
S133 F72 F74 F76

F71 F67 F65 F63 F61

F69 F66 F64 F62 F60

Name Protection (Function)

F60 +48 VDC Emergency stop circuit
F61 +48 VDC, MCU supply
F62 +48 VDC, CID supply
F63 +48 VDC, LID supply
F64 +48 VDC, Steering servo supply (electronic)
F65 Option: +48 VDC, GFU supply
F66 Option: +48 VDC, DC/DC transformer and DHU
supply
F67 –
F69 +48 VDC, Extra equipment supply
F71 +48 VDC, Capacitor charging
F72 +48 VDC, Steering servo supply (high current)
F73 Supply 48 VDC
F74 Status, key relay
F75 Option: Working light
F76 Option: Stereo/Camera
F77 Option: Seat heating
S133 Function: Emergency release of the mechanical
brake

20.4 Overview
See the following pages for electronic overview!

© BT Repair Manual RRE140/160/180/200/250 20 – 13

 Electrical diagram
Overview
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-01-09 7503877-040

21 21
1
27 27

29

B19 75
(X130:37) OUT.+15VDC
(X130:12) INP.HEIGHT SENSOR Main Lift A
MCU A5 1

30 76 95
R (X130:26) INP.HEIGHT SENSOR Main Lift B
29 B18 130 OUT.PARK
(X130:40) INP.HEIGHT SENSOR Free Lift A BRAKE 95

21
1
30 131
(X130:13) INP.HEIGHT SENSOR Free Lift B (X131:20) K20
1

R
21

27 73 P4 Q1
(X130:39) INP.MAIN LIFT HEIGHT REF. (A9)

32
88
B46 OUT.HORN (X131:25)
26
27 40
139 (X130:27) INP.MAIN LIFT HEIGHT REF.
OUT.(PWM) LEFT SUP. ARM (X131:39) 96
Q16
B57

26
BRAKE
OUT.(PWM) RIGHT SUP. ARM (X131:12) 97

F74 (A9)
30
27 141 Q17

3A
(X131:2) INP.FREE LIFT HEIGHT REF.

B58
32

27
80 (X130:24) INP.CABIN TILT, LOWER POS.

28
B28
27

28 28
30 INP.KEY POWER RELAY. STATUS (X131:6)
100
24

81
(X130:10) INP.CABIN TILT, UPPER POS.
98
B29 OUT.WARNING LAMP (X131:36)
> (X15:9) LID
> (X15:7) CID

30 P5

58
OUT.(PWM) MAIN MAST LOWER (X131:40)
Q4

27
B17
27 57 (X130:25) INP.STEERING 59
WHEEL180 DEG. OUT.(PWM) MAIN MAST LIFT (X131:26)
Q2
F63 (A9)
F62 (A9)

OUT.(PWM) REACH IN (X131:13) 60

7,5A

30
7,5A

(X130:20)OUT.GND.DIGITAL Q6
55 61
OUT.(PWM) REACH OUT (X131:41)
B31 84 Q7
90 (X130:31) INP.LEFT FOOT SWITCH
62
B32 OUT.AUX Dir. A (X131:37)
85 (X130:4) INP.BRAKE REF. 1 Q8
(2)
63
(6) OUT.AUX Dir. B (X131:11)
1 (3) 86 (X130:18) INP.BRAKE REF. 2 Q9
X3
34
(1) OUT.FAN, CHASSIS (X131:34) M G4
X1 87 (X130:17) INP.ACCELERATOR SIGNAL
27

(4)
66
OUT.TILT/SIDESHIFT AUX (X131:38)
Q18
+ -

G1
90 33
(X130:6) GND. ANALOG OUT.FAN,CONTROLLERS (X131:9) M
G3
X1
1

70
(X130:5) INP.BATT. VOLT. STATUS
71
(X130:19) INP. BATT.MEASURE 2
SHUNT

72 (X130:32) INP. BATT.MEASURE 1

27 83
(X130:41) INP.SEAT SWITCH
40
40 B49
INP.REACH CARRIAGE SENSOR 1 (X130:38) 78 27

55 (X130:1) OUT.+5VDC
B26
79
INP.REACH CARRIAGE SENSOR 2 (X130:11)
55 P 69
(X130:3) INP.LIFT PRESSURE 30 B27
B4 30
(X130:20)GND.
1

F60 (A9)

56 CAN1
(X130:29) GND ANALOG 117
15v (X130:23)
3A

118
Gnd (X130:34)
21
(X131:5) E.S.O. STATUS 119
20

H (X131:27)
21
1

120
L (X131:42)
S21
21

F71 (A9) R101

23
(X131:15) MAIN CONT./CAP CH.
7,5A CAN2
Q10 218
Gnd (X130:33)
31 (X131:7) OUT.MAIN CONT.
21 31 219
H (X130:22)
22 220
(X131:1) INP.+48VDC POWER L (X130:8)
1 8 40 (X131:14) GND, POWER
To T1

F61 (A9) 22 CAN 1

1
7,5A CAN 2
F72 (A9) 250
based on F64 (A9) 30A 9
1 9
255534 rev.C
03339L.wmf 3A

20 – 14 Repair Manual RRE140/160/180/200/250 © BT

 Electrical diagram
Overview
Order number Date Valid from serial number T-code
7503877-040 2009-01-09 6070557- 815, 816

= Height measuring
21

27

F69 (A9)
1 1 116 27
10A
95 95 40
S133
(A9)

27
F73 (A9)
26
7,5A
B1 14
(K1:1)THERMO ELECTICAL SENSOR IN M1
21
CID 11 (K1:6) Gnd. ACT
(X504:16) EMERGENCY
SWITCH OFF STATUS A1 10
(K1:11) +12VDC T1
12 (K1:13) Speed A
27
32 32 B11 13
(X504:17) OUT. KEY POWER RELAY (K1:14) Speed B
(U) 2
From 8
F1 3
28 28 Q10 (B+) (V) M
(X504:7) KEY POWER 325A 4
RELAY STATUS 40 (W)
(B-) M1
27 L (K1:16) 220
(K1:9) +48VDC LOGIC SUPPLY
CAN2 H (K1:8) 219

Gnd(K1:7) 218
27 41
(K1:2) OUT.(PWM) CAB TILT DOWN
24
Q21
From F62 (A9) (X504:18) +48VDC POWER
27 64 (K1:10)OUT.(PWM) CAB TILT UP
40 Q11
(X504:3) GND
19

42
B2 16
(K1:1) THERMO ELECTICAL SENSOR IN M1
(K1:6) Gnd.
ACH
(X504:14) +5V, STEER SENSOR 1
43
(X504:13) STEER SENSOR 1 PULSE A 15
(K1:12) CONTROLLER ID T2
44 (K1:11) +12VDC
(X504:4) STEER SENSOR 1 PULSE B 17
45 (K1:13) Speed A
(X504:5) GND B12 18 (K1:14) Speed B 5
B13 46 (U)
(X504:12) +5V, STEER SENSOR 2 8 6
47 (B+) (V) M
(X504:11) STEER SENSOR 2 PULSE A 7
From (W)
48
(X504:2) STEER SENSOR 2 PULSE A Q10
40 F3 325A
(B-) M3
27
(K1:9) +48VDC LOGIC SUPPLY
220
L (K1:16)
39
120ȍ

B20
CAN2

49 50 27 35
(X505:2) INP.LIFT/LOWER (K1:2) OUT.(PWM) LOWER
Q5 INITIAL H (K1:15)
219
B21 MAST (K1:8)
51 27 36 (K1:10) OUT.(PWM) LIFT
(X505:11) INP.REACH IN/OUT 218
Q3 Gnd(K1:7)

B22 52
(X505:17) INP.TILT

B23 53
(X505:3) INP.AUX 1 / SIDESHIFT 250
(X901:8) +48VDC
(X901:16) +48VDC
EPS
(1)
B35 (2)
93
(X505:5) INP.HORN REQUEST
9
A2
A6 (X901:6) INP.ENABLE
(4) B36 M
(3) 94 (X505:4) INP.TRAVEL DIR. CHANGE REQUEST
39

40 CAN 2
(X901:7) GND POWER M6 219
49

H (X901:2)
(X901:15) GND POWER 220
L (X901:10)
120ȍ

R202

100
LID P6
(X202: 2 +48VDC POWER)
B42 105
(X503:4) INP. 5TH LEVER, FUNCTION SHIFT 40
(X202:1 GND)

CAN 1 H L
(X202: 3 4)
49

49
39

120

(X505:10) GND. ANALOG

119

(X503:7) From F63 120ȍ

39 (A9)
(X505:1) +5VDC SOFTWARE CONTROLLER
(X503:1) R102
4 CAN 1
(X504:9)
119
(X504:15) CAN1 H 3 SERVICE KEY
118
120
(X504:8) 2 X41
(X504:6) CAN1 L 117
1
CAN 1
218
219
220

CAN 2
250

9
based on 255534 rev.C
03339R.wmf

© BT Repair Manual RRE140/160/180/200/250 20 – 15

 Electrical diagram
Overview
T-code Valid from serial number Date Order number
815, 816 6070557- 2009-01-09 7503877-040

WITHOUT HEIGHT MEASURING

O.T.P.(OPTIPACE)
from F73(A9)

27 75 (X130:12) INP.HEIGHT REF MAST MCU A5 A2

203 (X901:3) OUT.12VDC REF.SENSOR
NEAR LOWER POSITION
B33 211
(X901:11) OUT.STEER WHEEL REF
30
B59
202
27 73 (X901:12) OUT.GND.SENSOR
(X130:39) INP.MAST LOWER POS B
27

B46
27
139 (X130:27) INP.MAST LOWER POS B.
B57

30
27 141
(X131:2) INP.ORKS NEAR MAST TOP

B25
30

30
(X130:20)OUT.GND.DIGITAL

from F73(A9)

OUT.FORK SPREAD / AUX (X131:21) 65

Q12

27
OUT.AUX VALVE 3 (X131:10) 67 Q14

OUT.AUX VALVE 4 (X131:24) 68 Q15

B32
TRAVEL REQUEST

27 S29 91
(X131:16)INP.TRACTOR DIRECTION TRAVEL REQ.

S27 92
(X131:30)INP.FORK DIRECTION TRAVEL REQ.

TILT / SIDE SHIFT

27 74
(X130:16)INP.FORK TILT ANGLE
B5
30
TRAVEL ALARM
P7
B47 27
126 from F73(A9)
OUT.TRAVEL ALARM(X131:23)

27 SOUTH SENSING
1
111 TRAFFICATORS
2 (X131:18)INP.SIDESHIFT SENSOR,
LEFT SIDE P12
OUT.TRAFFICATOR LEFT(X131:8) 121
NORTH SENSING
112
3 (X131:32)INP.SIDESHIFT SENSOR,
30 RIGHT SIDE P13
4 122
OUT.TRAFFICATOR RIGHT(X131:35)

R10
27
from F73(A9)
680ȍ/2W

based on 255534 rev.C

03346L.wmf OPTION

20 – 16 Repair Manual RRE140/160/180/200/250 © BT

 Electrical diagram
Overview
Order number Date Valid from serial number T-code
7503877-040 2009-01-09 6070557- 815, 816

AUX.+48VDC (BATTERY) GENERAL FUNCTION UNIT SEAT HEATING

X42 X26 E10:1 SEAT E10:2 BACK REST

116
from CAN1(L) 120
4 129 S126 138 429
from F69(A9) from F77(A9) 40
119
40 from CAN1(H) 3
40
2
99
from F65(A9) 1
WORKING LIGHT

REAR LEFT REAR RIGHT

S99 E5 E6
190 191 193 40
from F75(A9)
CID E3 E4
192
A1
REAR LEFT REAR RIGHT

ELECTRONIC START KEY

DC/DC CONVERTERS

OUT. +5V DC (X506:1)

132
1 K1 109
T5
(6) INP.+48VDC
OUT. GND (X506:2) 133 2 40
(3) INP.GND
OUT. ENABLE (X506:3) 134 3 128
(4) OUT.+12VDC
OUT. SCK (SPI CLOCK) (X506:4) 135 4 X43 140
(5) OUT.GND.
INP. MISO(SPI DATA MASTER IN) (X506:5) 136 5

OUT. MOSI (SPI DATA MASTER OUT) (X506:6) 137 6

109
T6
from F66(A9) (6) INP.+48VDC
40 (3) INP.GND
224
AUX 2 / FORK SPREAD (4) OUT.+24VDC
X44 240 (5) OUT.GND.
39
B24 54 (X505:12) INP. AUX 2/ FORK SPREAD
49 DATA HANDLING UNIT/
SHOCK SENSOR.
NEXT HEIGHT LEVEL 109
A82 TV MONITOR

39
from F66(A9)
40
(1) INP.+48VDC
115
B50
(8) INP.GND. (103) GND.
B38 101 119 114
(X503:2) INP. HEIGHT PRE-SELECTION, (102) +12VDC
49
NEXT LEVEL
T20 (2) INP. CAN1 HIGH
120 156
HEIGHT LIM. OVERRIDE (3) INP. CAN 1 LOW (104) SCREEN
39 110
(101) VIDEO SIGNAL
49 B39 102
(X503:8) INP. HEIGHT LIMITATION,
OVERRIDE
27
B90
CABIN TILT
from F73(A9)
40
(1) INP.+48VDC
110
P14
(A:1) VIDEO SIGNAL
39 (2) INP.GND.
B43 119 156
106 from CAN1(H) (3) INP. CAN1 HIGH (A:2) SCREEN
(X503:10) INP. CABIN TILT REQUEST
49 114
120 (B:1) +12VDC
from CAN1(L) (4) INP. CAN 1 LOW
SPARE FUNCTION INP. 115
(B:2) GND.
39
49 B44 107
(X503:11) INP. SPARE FUNCTION 1
39
STEREO/CD
B45
49
108
(X503:11) INP. SPARE FUNCTION 2 T3
TILT / SIDE SHIFT 113 (6) INP.+48VDC
from F76(A9)
39 40
(3) GND.
B40 103 (X503:3) INP. FORK TILT, 114
49 ZERO DEGREE POSITIONING (4) OUT.+12VDC
115
39 (5) OUT.GND
B41 340
104 (X503:9) INP. SIDESHIFT LOAD INFORMATION DISP.. (2) OUT.GND
49 CENTRAL POSITION REQUEST 312

119
(X202:3) CAN1 H
P6 (1) OUT.+12VDC

120
49

49
(X202:4) CAN1 L. (A:4)+12VKEY
A11
39

(X505:10) GND. ANALOG 100 312

(X503:7) (X202:2) INP. +48VDC (A:7) INP.+12VDC
39 40 340
(X505:1) +5VDC SOFTWARE CONTROLLER (X202:1) INP. GND. (A:8) INP.GND
(X503:1)
(B:5) OUT.LEFT (+)
LT+
from F63(A9) P10 (B:6) OUT.LEFT (-)
LT-

RT+ (B:3) OUT.RIGHT (+)

P11
T4 RT-
(B:4) OUT.RIGHT (-)

OPTION based on 255534 rev.C

03346R.wmf

© BT Repair Manual RRE140/160/180/200/250 20 – 17

20 – 18

815, 816
T-code
Wiring diagram
Electrical diagram
BATTERY CONNECTOR
X3 SHUNT BAR
1 40
Sh. 2 Sh. 2

ELECTRONIC CARD, MAIN CONTROL UNIT

A5

40
X131:14 GND, POWER

X1 G1 X1
+ - 72
X130:32 INP. BATT. MEASURE 1
48V
X1 WHEN OPTION BATT. CHANGE POWER CABLES X17
71
X130:19 INP. BATT. MEASURE 2

Valid from serial number

6070557-
Repair Manual

20.5 Wiring diagram

70
X130:5 INP. BATT. VOLTAGE STATUS
MEASURING WIRES

21 21
Sh. 2 X131:5 INP. EMERGENCY SWITCH OFF
EMERGENCY SWITCH OFF STATUS
X20 S21 X20 Q10
20 1 2 21 A1 A2 31
Sh. 2 X131:7 OUT. MAIN CONTACTOR
RRE140/160/180/200/250

2 1

8
Sh. 2

2009-01-09
Date
23 23
Sh. 2 X131:15 INP. MAIN CONTACTOR / OUT.
CAP. CHARGE

22 22
Sh. 2 X131:1 INP. +48VDC POWER MCU

28 28
Sh. 2 X131:6 INP. KEY POWER RELAY STATUS

119/RD 119/RD
Sh. 3 X131:27 CAN 1 HIGH

7503877-040
Order number
R101 120
120/WH
X131:42 CAN 1 LOW

255534
© BT

1/ 23
03317.wmf
© BT

7503877-040
Order number
FUSE CENTRAL MODULE
A9

32 X15:2 F73 X15:29 27

Sh. 3 Sh. 4 +48VDC SUPPLY
7,5A
F74 X15:10 28
K20 Sh. 1 3 KEY POWER RELAY STATUS
3A
21 X15:4 A1 A2 F75 - OPTION X15:8 190
Sh. 1 3 Sh. 17 WORKING LIGHT
10A
F76 - OPTION X15:6 113
Sh. 18 STEREO/CAMERA CONVERTER SUPPLY
7,5A
1 X16:2 1 2 26 F77 - OPTION X15:3 129

2009-01-09
Sh. 1 Sh. 14 SEAT HEATER

Date
10A

F60 X15:1 20
Sh. 1 +48VDC ESO CIRCUIT
3A
F61 X15:5 22
Sh. 1 +48VDC MCU SUPPLY
7,5A
F62 X15:7 24
Sh. 3 +48VDC CID SUPPLY
Repair Manual

7,5A
F63 X15:9 100
Sh. 15 +48VDC LID SUPPLY
7,5A
F64 X15:19 9
Sh. 6 +48VDC STEER SERVO ELECTRONIC SUPPLY
3A
F65 - OPTION X15:28 99
Sh. 16 +48VDC GFU SUPPLY
5A
F66 - OPTION X15:25 109
Sh. 20 +48VDC AUX CONVERTERS SUPPLY, DHU SUPPLY
7,5A
X15:15

6070557-
Valid from serial number
F67 - NOT USED X15:24
RRE140/160/180/200/250

X15:14

F69 X15:23 116

Sh. 20 +48VDC BATTERY VOLTAGE, AUX EQUIPMENT SUPPLY
10A

EMERGENCY BRAKE RELEASE S133

2 1 X15:11

5 4 X15:20 95
Sh. 15 OUT. PARKING BRAKE

X15:22 40
Sh. 1 3 B-

8 F71 23

Electrical diagram
X16:1 X15:21
Sh. 1 4 Sh. 1 +48VDC CAP. CHARGE
7,5A
F72 X15:26 250
Sh. 6 +48VDC STEER SERVO POWER SUPPLY
30A
X15:27

X15:17

Wiring diagram
815, 816
T-code
255534
2/ 23 PROD C
20 – 19

03318.wmf
20 – 20

815, 816
T-code
Wiring diagram
Electrical diagram
ELECTRONIC CARD, CENTRAL INFORMATION DISPLAY
A1

X20 X499
24 24 24/BN
Sh. 2 X504:18INP. +48VDC POWER

X20 X499
40 40 40/WH
Sh. 2 4 X504:3 INP. GND

X20 X499
21 21 21/GN
Sh. 2 X504:16INP. EMERGENCY SWITCH OFF STATUS

Valid from serial number

6070557-
Repair Manual

X20 X499
32 32 32/GY
Sh. 2 X504:17OUT. KEY POWER RELAY

X20 X499
28 28 28/YE
Sh. 2 X504:7 INP. KEY POWER RELAY STATUS

X20 X500
119/RD 119/RD 119/YE-BN
h. 1 15 X504:15CAN 1 HIGH
RRE140/160/180/200/250

119/WH-GY
X504:9

X20 X500
120/WH 120/WH 120/GY-BN
h. 1 15 X504:6 CAN 1 LOW

120/RD-BU

2009-01-09
Date
X504:8

7503877-040
Order number
255534
3/ 23 PROD C
03319.wmf
© BT
© BT

7503877-040
Order number
MOTOR CONTROLLER, DRIVE
T1

F1
8 2
h. 2 5 B+
325A
+ U DRIVE MOTOR
M1
U
40 3 V
h. 3 5 B- V
W M
3~A

2009-01-09
THERMO ELECTRICAL SENSOR IN M1

Date
14 4
K1:1 W

B1

11 ELECTRONIC CARD, MAIN CONTROL UNIT

K1:6
A5
Repair Manual

10 218/BU
K1:11 +12VDC SUPPLY K1:7 X130:33 CAN 2 GND
SPEED MEASURING IN M1
B11
1 2 12 219/RD
K1:13 K1:8 X130:22 CAN 2 HIGH
+ B

4 3 13 220/WH

6070557-
Valid from serial number
K1:14 K1:16 X130:8 CAN 2 LOW
- A
RRE140/160/180/200/250

64 64
Sh. 11 K1:10 OUT. (PWM) CABIN TILT UP

41 41
Sh. 11 K1:2 OUT. (PWM) CABIN TILT DOWN

218/BU
Sh. 5
27 27
h. 2 5 K1:9 +48VDC LOGIC SUPPLY

219/RD
Sh. 5

Electrical diagram
ELECTRONIC CARD, MAIN CONTROL UNIT
A5 220/WH
Sh. 5
G3
1 2 33
M X131:9 OUT. FAN, CONTROLLERS

G4
+ -

Wiring diagram
34
M X131:34OUT. FAN, CHASSIS

815, 816
T-code
255534
4/23 PROD C
20 – 21

03320.wmf
20 – 22

815, 816
T-code
Wiring diagram
Electrical diagram
MOTOR CONTROLLER, LIFT
T2

F3
8 5
Sh. 4 B+
325A
+ U PUMP MOTOR
M3
U
40 6 V
Sh. 4 6 B- V
W M
3~A
THERMO ELECTRICAL SENSOR IN M3
19 7
K1:1 W

B2

Valid from serial number

6070557-
Repair Manual

16
K1:6

16 218/BU
K1:12 CONTROLLER ID K1:7 Sh. 4

15 219/RD
K1:11 +12VDC SUPPLY K1:8 Sh. 4 6
SPEED MEASURING IN M3
B12
RRE140/160/180/200/250

1 2 17
K1:13 K1:15
+ B
120

4 3 18 220/WH
K1:14 K1:16 Sh. 4 6
- A

27 27
Sh. 4 7 K1:9 +48VDC LOGIC SUPPLY

2009-01-09
Date
X22 Q5 X22
1 2 35
K1:2 OUT. (PWM) INITIAL MAST LOWER

Q3 X22
1 2 36
K1:10 OUT. (PWM) INITIAL MAST LIFT

7503877-040
Order number
255534
5/ 23 PROD C
03321.wmf
© BT
© BT

7503877-040
Order number
ELECTRONIC ASSY, STEER SERVO
A2

40 40
Sh. 5 14 X901:7 GND POWER

2009-01-09
Date
40
X901:15 GND POWER

250 250
Sh. 2 X901:8 +48VDC POWER SUPPLY
Repair Manual

M6
250
X901:16 +48VDC POWER SUPPLY
M
9 9
Sh. 2 X901:6 INP. ENABLE

6070557-
Valid from serial number
219/RD 219/RD
RRE140/160/180/200/250

Sh. 5 X901:2 CAN 2 HIGH

R202 120
220/WH 220/WH
Sh. 5 X901:10 CAN 2 LOW

203
X901:3 OUT. 12VDC FOR REFERENCE
SENSOR

211
X901:11 INP. STEERING WHEEL REFERENCE
POSITION

Electrical diagram
212
X901:12 OUT. GND FOR REF. SENSOR

Wiring diagram
815, 816
T-code
255534
6/ 23 PROD C
20 – 23

03322.wmf
20 – 24

815, 816
T-code
Wiring diagram
Electrical diagram
PEDALS BASIC MODEL

ELECTRONIC CARD, MAIN CONTROL UNIT

A5
X39 B31
55/RD 1
Sh. 8 X39
2 84
X130:31 INP. LEFT FOOT SWITCH
3

X39
90/BU
X130:6 GND, ANALOG

PEDALS

Valid from serial number

6070557-
Repair Manual

B32

X39
85/WH
6 2 X130:4 INP. BRAKE REFERENCE 1

X39
86/BK
3 X130:18 INP. BRAKE REFERENCE 2

X39
87/GY
RRE140/160/180/200/250

1 4 X130:17 INP. ACCELERATOR SIGNAL

X39 S29 X39

27 5 7 91
Sh. 5 8 X131:16 INP. TRACTOR DIRECTION
TRAVEL REQ.

2009-01-09
Date
S27 X39
8 92
X131:30 INP. FORK DIRECTION TRAVEL REQ.

255534

7503877-040
Order number
7/ 23 PROD C
03323.wmf
© BT
© BT

7503877-040
Order number
PEDALS ERGO MODEL

ELECTRONIC CARD, MAIN CONTROL UNIT

A5
X20 X35 B31
55/RD 1

2009-01-09
Date
Sh. 7 11 X35 X20
2 84
X130:31 INP. LEFT FOOT SWITCH
3

X35 X20
90/BU
X130:6 GND, ANALOG
Repair Manual

PEDALS
B32

X35 X20
85/WH
6 2 X130:4 INP. BRAKE REFERENCE 1

X35 X20
86/BK
3 X130:18 INP. BRAKE REFERENCE 2

6070557-
Valid from serial number
X35 X20
RRE140/160/180/200/250

87/GY
1 4 X130:17 INP. ACCELERATOR SIGNAL

X20 X58 S29 X58 X20

27 5 7 91
Sh. 7 9 X131:16 INP. TRACTOR DIRECTION
TRAVEL REQ.

S27 X58 X20

8 92
X131:30 INP. FORK DIRECTION TRAVEL REQ.

Electrical diagram
Wiring diagram
255534
8/ 23 PROD C
03324.wmf

815, 816
T-code
20 – 25
20 – 26

815, 816
T-code
Wiring diagram
Electrical diagram
ELECTRONIC CARD, CENTRAL INFORMATION DISPLAY
A1
B13
X27 X499
42/BK 42 42/BU
X504:14 +5VDC, STEER SENSOR 1

X27 X499
1 3 43/RD 43 43/RD
X504:13 STEER SENSOR 1 PULSE A
+ A

X27 X499
45/OR 4 2 44/BN 44 44/BK
X504:4 STEER SENSOR 1 PULSE B
- B

X27 X499
45 45/VT
X504:5 GND, STEER SENSORS

X27 X499
46/YE 46 46/GY-PK
+5VDC, STEER SENSOR 2

Valid from serial number

6070557-
X504:12
Repair Manual

X27 X500
5 7 47/BU 47 47/BN-GN
X504:11 STEER SENSOR 2 PULSE A
+ A

X27 X500
45/VT 8 6 48/GN 48 48/WH-YE
X504:2 STEER SENSOR 2 PULSE B
- B
RRE140/160/180/200/250

ELECTRONIC CARD, MAIN CONTROL UNIT

A5

2009-01-09
Date
B17
27 1 2 57
8 11 X130:25 INP. STEERING WHEEL 180 DEG.
3

30
h. 12

7503877-040
Order number
255534
9/ 23 PROD C
03325.wmf
© BT
© BT

7503877-040
Order number
ELECTRONIC CARD, CENTRAL INFORMATION DISPLAY
A1

39/RD 39/RD
h. 14 X505:1 OUT. +5VDC, SOFTWARE
CONTROLLED

X503:1

2009-01-09
Date
49/BU 49/BU
h. 14 X505:10 GND, ANALOG

X503:7
B20
Repair Manual

1
3 50/BK
X505:2 INP. LIFT/LOWER
2

B21
1
3 51/BN
X505:11 INP. REACH IN/OUT
2

6070557-
Valid from serial number
B22
RRE140/160/180/200/250

1
3 52/OG
X505:17 INP. TILT / AUX 1
2

B23
1
3 53/YE
X505:3 INP. AUX 2 / SIDESHIFT
2

B24
1
3 54/GN
X505:12 INP. AUX 3 / FORK SPREAD
2

Electrical diagram
B42
3
1 105/GN
X503:4 INP. AUX 4 / FIFTH LEVER B24,
2 FUNC. SHIFT

Wiring diagram
815, 816
T-code
255534
10 / 23 PROD C
20 – 27

03326.wmf
20 – 28

815, 816
T-code
Wiring diagram
Electrical diagram
ELECTRONIC CARD, MAIN CONTROL UNIT
A5

X22 Q4 X22
27 1 2 58
Sh. 9 12 X131:40 OUT. (PWM) MAIN MAST LOWER

X22 Q2 X22
1 2 59
X131:26 OUT. (PWM) MAIN MAST LIFT

X22 Q6 X22
1 2 60
X131:13 OUT. (PWM) REACH IN

Valid from serial number

6070557-
Repair Manual

X22 Q7 X22
1 2 61
X131:41 OUT. (PWM) REACH OUT

X22 Q8 X22
1 2 62
X131:37 OUT. AUX DIRECTION A

X22 Q9 X22
1 2 63
X131:11 OUT. AUX DIRECTION B
RRE140/160/180/200/250

X22 X37 X40 Q18 X40 X37 X22

27/VT 27 1 2 66 66/GY 66
X131:38 OUT. TILT / SIDESHIFT / AUX

X25 X49 Q12 X49 X25

1 2 65
X131:21 OUT. FORK SPREAD / AUX

X25 X49 Q14 X49 X25

1 2 67
X131:10 OUT. AUX VALVE

2009-01-09
Date
X25 X49 Q15 X49 X25
1 2 68
X131:24 OUT. AUX VALVE
CABIN TILT DOWN
X22 X56 Q21 X56 X22
1 2 41
Sh. 4
CABIN TILT UP
X22 X56 Q11 X56 X22
1 2 64
Sh. 4

7503877-040
Order number
55/RD 55/RD
Sh. 8 X130:1 OUT. +5VDC

X22 B4
X22
3 P 2 69
X130:3 INP. LIFT PRESSURE
1

X22
56
© BT

X130:29 GND, ANALOG

© BT

7503877-040
Order number
WITH HEIGHT MEASURING

ELECTRONIC CARD, MAIN CONTROL UNIT

A5

29
X130:37 OUT. +15VDC
B19
X22 X38 X38 X22
1 3 75

2009-01-09
INP. HEIGHT SENSOR MAIN

Date
X130:12
+ A
LIFT, PULSE A
X38 X38 X22
4 2 76
X130:26 INP. HEIGHT SENSOR MAIN
- B
LIFT, PULSE B
X22
Repair Manual

30 30
Sh. 9 13 X130:20 OUT. GND, DIGITAL
B18
X22 X37 X40 X40 X37 X22
29/YE 29 1 3 130 130/BK 130
X22 X130:40 INP. HEIGHT SENSOR FREELIFT,
+ A
PULSE A
X37 X40 X40 X37 X22
30/BU 30 4 2 131 131/RD 131
X130:13 INP. HEIGHT SENSOR FREELIFT,
- B

6070557-
Valid from serial number
PULSE B
RRE140/160/180/200/250

B58
X22 X37 X40 X40 X37 X22
27 27/VT 27 1 2 141 141/PK 141
Sh. 11 13 X131:2 INP. FREE LIFT HEIGHT REF.
3

B46
X38 X38 X22
1 2 73
X130:39 INP. MAIN LIFT HEIGHT REF

X38
3

X38 X38 X22

Electrical diagram
139
X130:27 INP. MAIN LIFT HEIGHT REF.

X38

Wiring diagram
255534

815, 816
T-code
12 / 23 PROD C
03328.wmf
20 – 29
20 – 30

815, 816
T-code
Wiring diagram
Electrical diagram
WITHOUT HEIGHT MEASURING

ELECTRONIC CARD, MAIN CONTROL UNIT

A5
B33
X22 X22
27 1 2 75
Sh. 12 14 X130:12 INP. HEIGHT REF. MAST NEAR
X22 LOWER POS.

3
30
Sh. 12 16

B25
X37 X40 X40 X37 X22
27/VT 27 1 2 141 141/PK 141
X131:2 INP. FORKS NEAR MAST TOP
X37 X40

3
30/BU 30

Valid from serial number

6070557-
Repair Manual

X38 X38
B46
X38 X22
1 2 73
X130:39 INP. MAST LOWER POS. A

3
B57
X38 X22
1 2 139
X130:27 INP. MAST LOWER POS. B
RRE140/160/180/200/250

2009-01-09
Date
255534
13/23 PROD C
03329.wmf

7503877-040
Order number
© BT
© BT

7503877-040
Order number
SEAT BACK REST
E10:1 E10:2

X47 X61 X62 S126 X62 X63 X63

129 138 429 ELECTRONIC CARD, MAIN CONTROL UNIT
Sh. 2 A5
B49
X47 X47
27 1 2 83
Sh. 13 15 X130:41INP. SEAT SWITCH

3
X47 X61
40

2009-01-09
Date
Sh. 6 15

P4

+ - IN 88
X131:25OUT. HORN
Repair Manual

6070557-
Valid from serial number
ELECTRONIC CARD, CENTRAL INFORMATION DISPLAY
RRE140/160/180/200/250

ELECTRONIC CARD, SENSORS A1

A6

39/RD 39/RD 93/VT

Sh. 10 17 1 INP. +5VDC OUT. HORN REQUEST 2 X505:5 INP. HORN REQUEST

49/BU 49/BU 94/GY

Sh. 10 17 4 INP. GND OUT. TRAVEL 3 X505:4 INP. TRAVEL DIR. CHANGE REQUEST
DIR. CHANGE REQUEST

Electrical diagram
Wiring diagram
255534
14/23 PROD C
03330.wmf

815, 816
T-code
20 – 31
20 – 32

815, 816
T-code
Wiring diagram
Electrical diagram
95 ELECTRONIC CARD, MAIN CONTROL UNIT
Sh. 2 A5

Q1
27 1 2 95
. 14 16 X131:20 OUT. PARKING BRAKE

X18 Q16 X18

1 2 96
X131:39 OUT. (PWM) BRAKE, LEFT
SUPPORT ARM
X19 Q17 X19
1 2 97
X131:12 OUT. (PWM) BRAKE, RIGHT
SUPPORT ARM
X20 X21 P5 X21 X20
3 1 98
X131:36 OUT. WARNING LAMP

X34 X21 X20

Valid from serial number

6070557-
118
Repair Manual

X130:34 GND, SERVICE KEY

X34 X21 X20

117
X130:23 +15VDC SUPPLY, SERVICE KEY

SERVICE KEY INTERFACE

X41
117 1
RRE140/160/180/200/250

118 2

X20 X21
119/RD 119/RD 3
Sh. 3 16
R102 120
X20 X21 ELECTRONIC CARD, LOAD INFORMATION DISPLAY
120/WH 120/WH 4 P6
Sh. 3 16
X34

2009-01-09
Date
119/RD
X202:3 CAN 1 HIGH

X34
120/WH
X202:4 CAN 1 LOW

X20 X21 X34

100 100
Sh. 2 X202:2 INP. +48VDC POWER

X20 X21 X34

40 40
Sh. 14 16 X202:1 INP. GND

7503877-040
Order number
255534
15/23 PROD C
03331.wmf
© BT
© BT

7503877-040
Order number
ELECTRONIC CARD, MAIN CONTROL UNIT
A5
B26
X22 X22
27 1 2 78
h. 15 17 X130:38 INP. REACH CARRIAGE SENSOR 1

3
B27
X22 X22
1 2 79
X130:11 INP. REACH CARRIAGE SENSOR 2

3
X22
30

2009-01-09
h. 13 17

Date
B28
X17 X17
1 2 80
X130:24 INP. CABIN TILT, LOWER POSITION

3
B29
X17 X17
1 2 81
Repair Manual

X130:10 INP. CABIN TILT, UPPER POSITION

3
X17

OPTION

6070557-
Valid from serial number
RRE140/160/180/200/250

GENERAL FUNCTION UNIT

CONNECTOR - GFU
X26
X20
99 99 1
Sh. 2

X20
40 40 2
Sh. 15 17

Electrical diagram
X20
119/RD 119/RD 3
Sh. 15 22

X20
120/WH 120/WH 4
Sh. 15 22

Wiring diagram
255534
16/23 PROD C
03332.wmf

815, 816
T-code
20 – 33
20 – 34

815, 816
T-code
Wiring diagram
Electrical diagram
B40
OPTION ELECTRONIC CARD, CENTRAL INFORMATION DISPLAY
A1
39/RD 3
h. 14 23
1 103/OG
X503:3 INP. FORK TILT, ZERO DEGREE
49/BU 2 POSITIONING
h. 14 23

ELECTRONIC CARD, MAIN CONTROL UNIT

A5

Valid from serial number

6070557-
Repair Manual

X22 X37 X40 X53 X53 X40 X37 X22

27 27/VT 27 27/WH 74/GN 74 74/GN 74
h. 16 22 X130:16 INP. FORK TILT ANGLE

X22 X37 X40 X53

30 30/BU 30 30/BN
Sh. 16 ELECTRONIC CARD, CENTRAL INFORMATION DISPLAY
A1
B41
3
1 104/YE
X503:9 INP. SIDESHIFT, CENTRAL
RRE140/160/180/200/250

2 POSITION REQUEST

SIDE SHIFT SENSOR

B47

27/BN 1 ELECTRONIC CARD, MAIN CONTROL UNIT

A5
SOUTH SENSING

2009-01-09
Date
X40 X37 X22
2 111/WH 111/BN 111
X131:18 INP. SIDESHIFT SENSOR, LEFT SIDE

NORTH SENSING
X40 X37 X22
3 112/BK 112/WH 112
X131:32 INP. SIDESHIFT SENSOR, RIGHT SIDE

30/BU 4
WORKING LIGHT

7503877-040
REAR LEFT REAR RIGHT

Order number
E5 E6
193

FRONT LEFT FRONT RIGHT

X20 X21 X32 S99 E3 E4
190 3 4 191 192
© BT

Sh. 2

X20 X21 X32

© BT

7503877-040
Order number
OPTION DC/DC CONVERTER
T3

X20 X30 STEREO/CD

113 113
Sh. 2 6 INP. +48VDC

X20 X30
40 40
Sh. 17 20 3 INP. GND

114 114
Sh. 19 4 OUT. +12VDC

2009-01-09
Date
115 115
Sh. 19 5 OUT. GND (GALV. SEPARATED)

X23 X30
340
2 OUT. GND (GALV. SEPARATED)
Repair Manual

X23 X30
312
1 OUT. +12VDC

STEREO/CD
A11

6070557-
Valid from serial number
312
A:7 INP. +12VDC
RRE140/160/180/200/250

A:4 +12V KEY

340
A:8 INP. GND

P10
LEFT +
B:5 OUT. LEFT (+)

LEFT -
B:6 OUT. LEFT (-)

Electrical diagram
P11
RIGHT +
B:3 OUT. RIGHT (+)

RIGHT -
B:4 OUT. RIGHT (-)

Wiring diagram
T4

815, 816
T-code
255534
18/23 PROD C
20 – 35

03334.wmf
20 – 36

815, 816
T-code
Wiring diagram
Electrical diagram
OPTION
FORK COLOUR CAMERA

FORK CAMERA TV-MONITOR

Valid from serial number

6070557-
Repair Manual

B50 P14

X50 X40 X48 X25 X23 X28

110 110/WH 110 110
VIDEO SIGNAL 101 A:1 VIDEO SIGNAL

X50 X40 X48 X25 X23 X28

156 156
SCREEN 104 A:2 SCREEN

X50 X40 X48 X25 X23 X28

RRE140/160/180/200/250

114 114/BN 114 114

+12VDC 102 B:1 +12VDC

X50 X40 X48 X25 X23 X28

115 115/GY-PK 115 115
GND 103 B:2 GND

2009-01-09
Date
X30
114
Sh. 18

X30
115
Sh. 18

7503877-040
Order number
255534
© BT

19/23 PROD C
03335.wmf
© BT

7503877-040
Order number
AUX 48VDC BATTERY VOLTAGE CONNECTOR
X42
X20
116 116 1
Sh. 2

40 2

2009-01-09
Date
OPTION DC/DC CONVERTER
T5

X20 X45 DC/DC CONVERTERS

Repair Manual

109 109
Sh. 2 22 6 INP. +48VDC

X20 X45
40 40
Sh. 18 22 3 INP. GND
X43
12VDC OUTLET
X36 X45
+ 128

6070557-
Valid from serial number
4 OUT. +12VDC
RRE140/160/180/200/250

X36 X45
- 140
5 OUT. GND (GALV. SEPARATED)

DC/DC CONVERTER
T6

109
6 INP. +48VDC

Electrical diagram
40
3 INP. GND
X44
24VDC OUTLET
X36 X45
+ 224
4 OUT. +24VDC

Wiring diagram
X36 X45
- 240
5 OUT. GND (GALV. SEPARATED)

815, 816
T-code
20 – 37

255534
20/23 PROD C
03336.wmf
20 – 38

815, 816
T-code
Wiring diagram
Electrical diagram
OPTION
ELECTRONIC START KEY

LECTRONIC START KEY ELECTRONIC CARD, CENTRAL INFORMATION DISPLAY

1 A1

132/PK 132/PK
1 X506:1 OUT. +5VDC

133/WK-BK 133/WK-BK
2 X506:2 OUT. GND

134/WH-BN 134/WH-BN

Valid from serial number

OUT. ENABLE

6070557-
3 X506:3
Repair Manual

135/WH-RD 135/WH-RD
4 X506:4 OUT. SCK (SPI CLOCK)

136/WH-OG 136/WH-OG
5 X506:5 INP. MISO (SPI DATA MASTER IN)

137/WH-YE 137/WH-YE
RRE140/160/180/200/250

6 X506:6 OUT. MOSI (SPI DATA MASTER OUT)

2009-01-09
Date
255534
21/23 PROD C
03337.wmf

7503877-040
Order number
© BT
© BT

7503877-040
Order number
OPTION
DATA HANDLING UNIT ELECTRONIC CARD, DATA HANDLING UNIT
A82

X52
109 109

2009-01-09
Date
Sh. 20 1 INP. +48VDC SUPPLY

X52
40 40
Sh. 20 8 INP. GND

X52
Repair Manual

119/RD 119/RD
Sh. 16 2 INP. CAN 1 HIGH

X52
120/WH 120/WH
Sh. 16 3 INP. CAN 1 LOW

6070557-
Valid from serial number
T20
RRE140/160/180/200/250

OPTION
SHOCK SENSOR
SHOCK SENSOR
B90

X52
27 27
Sh. 17 23 1 INP. +48VDC SUPPLY

Electrical diagram
40
2 INP. GND

119/RD
3 INP. CAN 1 HIGH

Wiring diagram
120/WH
4 INP. CAN 1 LOW

815, 816
T-code
255534
20 – 39

22/23 PROD C
03337.wmf
20 – 40

815, 816
T-code
Wiring diagram
Electrical diagram
B38
OPTION ELECTRONIC CARD, CENTRAL INFORMATION DISPLA
A1
39/RD 3
Sh. 17
1 101/BK
X503:2 INP. HEIGHT PRE SELECTION, NEXT
49/BU 2 LEVEL
Sh. 17
B39
3
1 102/BN
X503:8 INP. HEIGHT LIMITATION, OVERRIDE
2

Valid from serial number

6070557-
Repair Manual

B43
3
1 106/VT
X503:10 INP. CABIN TILT REQUEST
2

B44
3
1 107/GY
X503:5 INP. SPARE FUNCTION 1
2

B45
RRE140/160/180/200/250

3
1 108/WH
X503:11 INP. SPARE FUNCTION 2
2

ELECTRONIC CARD, MAIN CONTROL UNIT

A5

X20 X23 X29 X29 X23 X20

27 121
OUT. TRAFFICATOR LEFT

2009-01-09
Date
Sh. 22 X131:8
680~E/2W
X29 X23 X20
122
X131:35 OUT. TRAFFICATOR RIGHT

X24 X24
126
X131:23 OUT. TRAVEL ALARM

7503877-040
Order number
X20 X25 X25 X20
123
X131:17 INP. SPEED REDUCTION

255534
© BT

23/23 PROD C
03337.wmf