The truck series 394 H 40 -H 50 Productinformation The BR 394 diesel truck 304.00 Power is redefined with the new generation of fork trucks H 40, H 45 and H 50 for very heavy duty: Unequalled operating comfort increases productivity, which, together with fuel economy and low service costs, translates into superior economy. Design of operator's compartment Tho operator's compartment, developed accor- ding to the ergonomic findings, has an automo- bile-type qualty, options like radio, heating and air conditioning are perfectly integrated in theca bin, numerous places to pul things complete the picture. The indicatorsand switshes installed in the canopy console of the truckare easily acces sible, All mast functions can be operated sensi- {ively withthe Linde Load Control; the two levers integrated in the arm rest respond to the sligh- test movement ofthe finger. Also faligue-free is the Linde dual-pedal control for fast reversing ‘without shifting the feet; annoying road bumps are damped by the rubber-mounteddrive axle. A iow driving noise relieves the operator and ervi- ronment and ensures, together with an excellent panorama view, the high safety standards. Chassis. The unit of overhead guard and chassis (Linde ProtectorFrame) guarantees the greatest pos- sible stability and protection. The clsedchassis prevents dust and foreign particles from penstra- ting the assemblies. The engine bonnet canbe opened wide, additional access covers make the fast servicing easier. Engine ‘The low-noise diesel engines convince with their state-of-the-art engine technology: high torque, fuel economy, low exhaust emissions (NOx, CO, HC), low soot emissions. Drive No clutch, no transmission, no brako: The stop: less Linde hydrostatic drive excels especially in extreme applications due to itsiow-wear techno- logy Electronic / electrical system The Linde Truck Control (LTC) adjusts the engine speed intelligently to the particular domand of the hydraulic system and can be adapted individually to any task. All safety-related truck components such as microprocessors exist twice: a seltt-iest makes servicing easier. The protection of the control unit and electris cables against moisture and dirt complies with the highest automotive standard andalsoiner. ases functional reliability.0. Product information The BR 394 diesel truck Steering ‘The hydrostatic steering responds withoutnearly any play. The ergonomic steoring whee! with adjustable fit angle fits easily andprecisely in the driver's hands. Mast Overhead tit cyinders alow the full load capa- city and a high residual capacity even at high liftheights. Slim mast channels ensure unobst- ructed view on the load and environment, main- tenance-free rubber-mounted coupling points ‘dampen impacts and vibrations and the electro- niclimkation of te tit angle bring the mast genty and quietly in the end position. bate | Three independent brake systems ensure grea test possible safety: * Gentle hydrostatic braking as soonas the accelerator is released means wear-tree deceleration in everyday operation. + Emergency braking by depressing the brake pedal (hydrostatic braking and added dece- leration by maintenance-free multiple disc brake. | ‘+ Automatic application of the parking brake when the engine of the vehicle is shut off. Safety is our prime concern Particular highlights are: + Excellent ergonomics freeing the operator of allunnecessary tedious tasks so that the operator can work nearly fatigue-free. + The hydrostatic drive brakes automaticelly when the accelerator pedalis released. + The noise level is very low, signals from the surroundings can be heard well. + Allsafety-related truckcomponents exist twice (redundant) for highest functional safety. + High degree of safety and stability due to tho Linde ProtectorFrame. + Superb visibility through the mast, excellent fsibilty and visibility upwards through sad guard, + Full d@dcapacity up to high lft heights and high ual eapacty ii oOKte. ‘+ The line safety valve prevents that the fork carriage drope uncontrollad with the load Ifa lifting hydraulics supply line is damaged. + Duo-sensitive safetybelt, Good driving characteristics in curves and pre- cise steering are naturally characteristic of this series, ‘Standard equipment ‘+ Hydraulically cushioned full suspension seat with a comprehensive range of settings. + The Linde double pedal control forall driving motions andthe Linde Load Control for relaxed ‘and precise operation ofall mest functions. + Airilterwith integrated oycione separaior ‘+ High-performance hydraulic fiter concept for ‘maximum purity of the oll and the optimum Service life of all hydraulic components. + Anti-glare display with indicators, for example, for fuel level, time, operating hours, service information and indicatorlightstorallimportant truck functions. * Variousplaces toputthings forwriting utensis, beverage cans, etc. + SEtyres. + Standard mast, lfha= 3100/3000 mm (H 40, H45/H50). + Forks, |= 1000 mm, + Forkcarriage wicth b: 1350mm. Options ‘+ Single-pedal model with directional switch in the arm rest. ‘+ Standard masts with iting heights ranging from 3000 to.5400 mm. + Duplex masts (ful free lit) with iting heights ranging from 3030 to 4130 mm. + Triplex masts (ful free lit) with lifting heights ranging from 4525 to6315 mm. + Load screen. ‘+ Single and double auxiliary hydraulics for al mast types. + Single-lever operation ofthe lifting hydraulics. * Various forklengths. + Ovorhoad guard canbe extended 2s faras the operator's compartment with roof, frontand rear windscreens and doors (also with tainted panes). + Wiper-wash system for front, rear and roof windscreens. Senice Training 394 604 2401 EN— 01/2005! } FRCOCUCUUCOUU UHH TET e ew eK we wewwwewwewe ee Gite. + Seats with improved comfort (lordotic support, ‘seat heater) and adjustment settings. ‘+ Warm water heating with integrated pollen filter. * Airconditioning with integrated pollen filter. + Radio with casseite deck and loudspeakers. ‘© Roof blind, clipboard, interior lighting, steering column also height-adustable, * Truck lighting, working lights. + Mirror. =01/2005 Senice Trang 384804240 Product information O The BR 394 diesel truck Road kit Integrated soot fiter for diesel Dust ejector ‘Acoustic alarm when reversing, omnidrectio- nalstrobe and turn signal lights. ‘Volumetric filing with low-fuel level waming in the display. Biodiesel fuel (RME) capably. Custom painting 030 Product information Liste. Diagnosis LTC - basic structure 302_00-40 Intemal combustion engine 1 Joystc 6 2 Displ 7 Pedal group 3 Mast||) 8 Directional controt switch 4 Directionalcontiol vaive block 9 Integrated traction contrat 5 Traction pump ‘Service Training - 994 8042401 EN—01/2005,Gate Product information O Diagnosis System communication - overview and > position of modules ‘Service Training ~ 89a 80a 2407 EN— 01/2005 05Q Productinformation LTC modules - difference between diesel and LPG trucks |LP.gas,no engine diagnosis, |LPG shutof valve Jgntion contol urit Inlemnalcombustion engine Disol, witn engine diagnosis WW dagnosis (ISO) engine control Injocton system Internal combustion engine Immebiizer Bervice Training -394 804 2401 EN 01/2005Diagnosis Product informatio e-60 Z6e ‘Scout 7a ining 394 604 2401 EN—O1/20050 Product information Diagnosis Joysticks Display ‘CANbus! CAN diagnostic connector Tilt angle sensor mast Mact Traction pump Directional control valveblock Pump control Internal combustion engine Injection system LTC- system overview 12 13 14 15 16 7 18 19 20 Engine speed sensor Engine control unit VW diagnosis CAN bus Il Fen Immobilizer Fuel shut-off valve Pedal group Directional control switch Integrated tractionvitcontrot LTC module 392_00-44 Display CANbus! CAN diagnostic comector YW dagnosis (ISO) sone avon Immobiizer ‘WW engine control unit CAN bus Il Integrated tractiorviftcontiol LTC module ‘Service Training - 394 804 2401 EN 01/2005,Gixtle Product information Q Diagnosis Composite instrument- fault codes > ‘The error codes are shown in the text field (1) (2x11 characters) andin case an “optional soot filter is fitted, its residual capacity. ‘The sequence in which thaerrorcodas are shown depends on the one hand on the code letter (T before L before D... error) and on the other hand fromthe sequenes in which the error numbers. ie are transmitted on the CAN. If more faults have occurred than can be shown, the list must be scrolled with the button. Inthe eventoi characters "<"in the text fiald soroll with the left button to the lett and in the eventot characters “>’in the text field scroll with the right button to the right. { Priotity of error code display: T before L before D —- ! dolore F bofore Rbefore X before Y before Z 1 Textfietd fe oir Traction feet Lit 1 D. Display I Tle Soot fiter FR Recorder (dalaloggon) ; XY.z_ [CSMites | ‘An engine fault message is indicated by a flas- | hing of the preheating indicator. (a) NOTE Errorcodes and possible remedial action are outputied and evaluated vie the diagnostic pro- gram*Pathfinder’. ee a a ae ae ee re we LTC traction control codes, release 1.0.0 (Gondiions eens mS i Error accelerator potentiometer zero position or 6 V potentiometer supply fault after ignition ON, B Accelerator potentiometerin zero position is Brake pedal not yet actuated after ignition ON a Seat not occupied 5 [Speed restriction active é Directional control switch in zero position (single-pedal model) 8 Brake pedal depressed hell way 2 [Brake pedal depressed fully 10, Intervention by working hydraulics requested it trol unit in programming mode Service Training - 304 801 2401 EN— 01/2005 0.0 Product information Rte Diagnosis 18 Safely relay: Voltage under 8 V 14 "Tarmival 15: Voltage under V 16_||__ | intervention by data logger requested 171] [intervention by soct fter requested 18 ‘Door not closed (only in trucks with door switch) 79 [Teaching of accelerator potantiomoter net yel performed Warnings Meaieaient See See ae eS ‘Signals of seat switch and accelerator potentiometer not plausible for more than 2 se- conds ‘Seat switch signals overlapping for morethan5 s ‘Coolant temperature sending urit: Signal outside of valid range 1__ [Hydraulic ol sensor: Signal outside of valid range 450 || |__| Throttle plate colenoid: Current too low (LPG trucks only) 157 [iid Fan bypass vaive: Current too high 158 |//||__ | Fan bypass valve: Current too low 159 ||| ‘Throttie plate solenoid: Current too high (LPG trucks only) 160 [||| | Throttio plate solenoid never activated (LPG tucks only) 167 |||) _ | Power tage of fan bypass valve always activated 168 ||| _ | Power stage offan bypass valvenever activated 169 |||] _ | Throttie plate solenoid always activated (LPG trucks only) >. 175 I Fault in throttle plate solenoid cirouit (LPG trucks only) 179 |||, | Faultin the fan bypass valve circuit 180 ||| __ | No data from safety processor [220 Invalic truck type 221 Produstion teatnot OK 222 EEPROM error ae Directional contol swith: Drecion signal oveaps zero satig signal or more han 8 a "The switch-controlied speed limitation function is activated andthe corresponding sig- nals of the switch (change-over contact) are not compatible. Fey ‘Accelerator: Signals of reference potentiometer and watchdog potentiometer nol plau= le 232, ‘Accelerator: Reference potentiometer cable breakage or short 233) ‘Accelerator: Reference potentiometer cable breakage or short 235) Directional control switch: Signals not plausibie 236) Directional control switch: All inputs open (eg coded connector missing) 237, Brake: Semi-actuaiion signals not compatible 238 | Brake: Normally closedcontact switch 1 and switch 2 not plausible 239 [11 [Seat switen: Signals not plausible 240 ||| [Power stage of LPG shut-ofl valve never activated (LPO trucks only) 2a II BV supply voltage for sensor toolow [243 |/|| _ | Safety relay does not close Safety relay does not open ‘Service Training —394 804 2401 EN 01/2005,! LR Productinformation 0 i Diagnosis | i t (245 Power stage release: Activation and feedback not plausible J |) [246 Power stage of release valve never activated ' 27 Faslease valve: Current toolow Bae ‘Speed sensing fault | 249 LPG shutoff valve: Current too low (LPG trucks only) 250 Throttle plate solenoid: Currenttoo low (LPG trucks only) 251 Brake valve: Current co high (only for trucks with retarderbrake) ( 252 Brake valve: Current too low (only for trucks with retarder brake) ' 253 | Bump forward: Currenttoohigh — | 254 Pump forward: Currenttoolow | [255 Pump reverse: Currenttoohigh 258 Pump reverse: Currenttooiow ! |) [as0 Throtile plato eolenoid: Currentioa high (LPG truoke only), ' ||| [260 “Throtile plate solenoid never activated (LPG trucks only) ' , [eet Power stage of brake valve always activated (tracks with brake valve only) ' | [262 Power stage of brake valvenever activated (trucks with brake valve only) | 283 ‘Power stage for pump forward always activated 264 Power stage fer pump forward never activated ' 7 [265 Power stage for pump reverse always activated t | [266 Power stage for pump reverse never activated ' 268 Throttie plate solenoid always activated (LPG trucks only) ' 270 Safety processor detects deviating signal rom speed sensor | 274 ‘Safety processor detects deviating value to SV supply voltage 272 Safety processor detects deviating signal from truck accelerator potentiometer | 273 Safety processor detecis deviating signal current pump forward ' Eazy ‘Safely processor detecis signals deviating from drectonal control switch ' 275 Fault in throttle plate solenoid circuit (LPG trucks only) ' 276 Faultin brake valve circuit (tucks with retarder brake only), I 277 Fault in pump forward Grout 278 Fault in pump reverse circuit h 340 Power stage of LPG shutofi valve always activated (LPG tucks only) ' 345, Rlolease valve: Maximum current excooded ' [346 Power stage of release valve always activated , [347 Release valve: Currentioo high b 348 Gas shutoff valve: Manimum current exceeded (LPG trucks only) } 349 LPG shut-off valve: Currentitoo high (LPG trucks only) | [B50 ‘Throttio plate solenoic: Current zero with power stage activated (LPG tracks only) , | [ase Brake valve: Current zero with powerstage activated (only for trucks with retarder brake) b | [354 Pump forward: Currentzero with power stage activated ' |. [356 Pump reverse: Currentzero with power stage activated , | |a70 Safoty proseasor detools deviating feedback signal at PWM powor stags for IG engine actuators ' I la71 | Safety processor detects deviating feedback signal at PWM power stags forhydrostatio, , actuators: ) 372 Salety processor detects deviating signal at operator inputs > | Senice Trainng=304 904 2401 EN 01/2005 on N=Om 0 Product information Diagnosis 373_|__ | Safely processor deteots deviating signal or pump reverse current + 374) Safety processor detects deviating signal pedal coding « 3801] [No data trom safety processor 481 || | Safety processor: truck epoedioo high 482 Safely processor: truck speed ico low % ‘493 ||__ [Safety processor: pump controlin forward drecton not plausible in relation to acceler: » tor potentiometer > a Salely processor: pump control in reverse direction not plausible in relation to accolora tor potentiometer co Safely processor: Activation of pump reverss nol plausible fo aceeleralor potentiometer x 408. Safety processor: LPG shutoll valve activated at speed 0 (LPG trucks only) 2 90 Tf] [Safe processor: Sich -ftest faut idl Lift Control Codes, Version 1.0.0: [ Stata a ee Se t 1__ |||, [Power On, procecure not completed 2 |) |soysiick neutral a FTiting at the stop, end posiiion damping active or programmed po , 4_|[]]_ [Programmed end position exceeded t 5 ||) [Invalid truck type 7 ir Doornot closed (only on trucks with door switch) 7] Control unitin programming mode 12 Ii Safely processor not active 14 |, [Terminal i: Voltage under V 15 EEPROM fault ‘ 16 Mastpositioning active 4 17 ‘Seatswitch not actuated t : 18 not 19 No teaching of joysticks 20 ‘Switching from 2nd to 3rd auxiliary hydraulics results in implausible signalsbriety ‘ WainiGSeh gine Ata aa ee RR OM RR 141 Incompatibility between signal/reterence signal seat switch. 146 Seat switch: Seat not occupied for more than 2 seconds 180 No data from safely processor 220 Tilt sonsor cable breakage zat Reference potentiomeler it sensor incompatible [223] | Joystick not in neutral position for more than 2 sea after Power On 230) Cable breakage joystick lifingllowering ; ee Ealll Cable breakage joystick tilting 2321) (Cable breakage joystick AUXT 208) [Cable breakage joyatick AUXt Incompatibility between sianal/eterence potentiometer liftinglowering oe ~~ “Service Training ~ 384 8042401 EN - 01/2005~-- eve - ese ewe ewweweeewewesvesesveceueeeewy =9 Lt. Product information O Diagnosis 236 Tacompatiilty between signal/reference potentiometer tilting 237 Incompatibility between signal/roference potentiometer AUXt 238 Incompatibility between signal/reference potentiometer Aux? 239 | Incompatibility between signal/reference signal seat switch 247 | Switching from 2nd to 3rd auxiliary hydraulics constantly results in implausible signals 250 Monitoring PWM (pulse width modulation) lifting/lowering oa 251 Monitoring PWM titing 252 ‘Monitoring PWM AUXT 253 Monitoring PWM AUX2 254 Solenoid current ifing/lowering too low 255 Solencid current titing 100 low 256 Solenoid current AUX1 too low 257 Solenoid current AUX2too low 258 Solenoid current lfinglowering too high 250 Solenoid current ling toa high 260 ‘Solenoid current AUX too high 251 ‘Solenoid current AUX2 too high 262 Voltage allifting solenoid permanenty high 283 ‘Voltage allowering solenoid permanently high 284 Voltage atforward iting solenoid permanently high 285 Voltage at backward titing solenoid permanently high 266 Voltage at solenoid AUX1+ permanently high 287 Voltage at solenoid AUX1- permanently high 288 Voltage at solenaid AUX2+ permanently high 289) Voltage at solenoid AUX2- permanently high 270) Voltage attliting soleroid permanently low’ 271 Voltage at lowering sobnoidpermanentlylow. Voltage at forward ttirg solenoid permanently low Voltage al backward lling solenoid permanently low Voltage ai solenoid AU + permanently low Voliage at solenoid AUH- permanently low Voltage at solenoid AU2+ permanently low Voltage al solenoid AUY2= permanently low Safety relay always Of Safety relay alvaysOffferPonerOn Safety relay always Or Z Safety relay always Oj after Power On Lowering release val 2 current too low although activated Towering release vaire current too high although not activated jvive current very bigh /e always OFF Lowering release ve always ON Safaly valve currentt w although activated Lowering release vali current too high although not activated Lowering release vale current very high Service Trang = 3048042407 EN 20050 Product information Diagnosis 292 Safety valve always OFF 203__|_|Safety valve alwaye ON 294 SV power supply too low 295 Production test not OK 350 [Safety processor detects deviating ifting/lowering joystick signal 354 Safety processor detects deviating tiling joystick signal 352 Safely processor detects devietingjoystick AUX signal 353 Safety processor detects deviating joystick AUX2 signal 354 Safety processor detects devieting PWM of ifting/lowering joystick 55 | | Safety processor detects deviatingtilting PWM 256 Safety processor dotects dovieting AUX 1 PWM. 37 Safety processor detects deviating AUX 2 PWM 358 No teaching of titangle limit stops in safety processor 359 Safety processor detects deviating tit angle signal 380 No cata from safely processor a0 Safely processor: Lifting, PWN high thoughjoystick signal low a4 Safety processor: Lowering, PWM high although joystick signal iow a2 ‘Safety processor: Forward tit, PW high though joystick signal low 413 Safely processor: Backward ti, PWM high though joystick signal low a4 ‘Safely processor: AUXT+, PWM high though joystick signal low na ‘Safety processor: AUXT-, PWM high though joystick signal low a6 ‘Safety processor: AUX‘, PWM high though joystick signal low a7 ‘Safety processor: AUX2-, PWM high though joystick signal low a8 Safely processor: Safely valve switch-off test unsuccesstul a9 Safely processor: Safty relay ewitch-off test unouocoostul 420) Safety processor: Lowering release valve switch-off test unsuccessful 424 Safety processor: Intemal signals PWM liftin/lowering incompatle a2, ‘Safely processor: Internal signals PWM tiling incompatible 423 Safely processor: Intermal signals PWM AUX? incompatible 424 Safely procossor: Internal signals PWM AUX2 incompatible 4257 Safety processor: Internal PWM signals error 426 Safety processor: Forward tit driven although mast outside oftie front electic stops a7 Saiey proceso: Bacay tt conte although mastoutsve of the behind electric, LTC codes of composite instrument Waringeitie ats ca ana eae Se in a ae 152 General fault of composite instrument 54,1) __ | Composite instrument CAN interface over 200 msin the bus-olf e2paition 156 Traction control heartbeat message missing ferover400me 154 Lift control heartbeat message missing for over 400 ms 760) ‘Soot ter control /heartbeat message missing for over 400 ms i 162 Datalogger /hearibeat message missing forover 400 ms E 164 (ESM2 CAN /nearibeat message missing for over 400 ms Senvoe ang 949082401 EN=0112008See ee Ee Te eee eee eee ee ee ee eT | Axtte. Productinformation 0 Diagnosis 166 (CSM 2 CAN /hearibeat message missing forover 400 ms 168 (CSM SCAN heartbeat message missing for over 400 ms 82 Display bulton pressed for over 1208 184 Oi pressure control signal shorted to earth and engine speed < 10pm. re UD altemator <8.2V for t> 300 ms and engine speed > 900 rpm orf battery charging ‘warning light signal OFF and engine speed < 10 rpm. 188 Air filtor restricted signal shoriodto earth and engine speed = 10 rpm ia ‘Signal of differential pressure of hydraulic system oll micro-filter shorted fo earth and engine speed < 10 pm - 792 ‘Selected characteristic doos not match the signals of the fuel level sending unit Serves Training ~394 604 2401 EN—01/2005 a