394

Seminar BR394
394

History
394

BR352

Productionstart: 11/1988

Trucks total: around 35000

394

Present and Future

394

The new Linde

394

BR394
H40/45/50
 394

BR394
Market release (Diesel): H40/45/50

Germany January 2004

Europe March 2004
World 3th Quarter 2004

Market release (LPG): 3th Quarter 2004

394

BR394
H40/45/50
394

BR394
H40/45/50
394

BR394
H40/45/50
394

H40/45/50 drivers compartment

Why Edgar likes to work more as to go to work.

394

H40/45/50 drivers compartment

394

Engine
Diesel
394

Volkswagen BJC engine

394

Volkswagen BJC engine

•engine type BJC (TDI with intercooler)

•number of cylinders 4
•cubic capacity 1896ccm
•power output 53 KW at 2600rpm
•max torque max 215Nm at 1800rpm
•nozzle pressure 230bar
•combustion pressure 25-31bar
•lower idle speed 1000rpm
•upper idle speed 2700rpm
394

Volkswagen BJC engine

•valve clearance automatic compensation

•firing order 1-3-4-2
•cylinder 1 opposite power output side
•thermostat 87° start - 102° fully open
•fuel diesel >49CZ RME possible
•number of teeth 135
394

Volkswagen BJC engine

394

Volkswagen BJC engine

394

Volkswagen BJC engine

starter

alternator 70 Ah
(90 Ah = SA)

aircompressor
394

Volkswagen BJC engine

belt concept

alternator

alternator

aircompressor
394

Engine system BJC BR394

diagnosis
port 6X2
394

Engine system BJC BR394

394

charge pressure control BJC BR394

394

Intercooler BJC BR394

charge air
intercooler
„IN“ charge air
hyd. oil
„OUT“

water
394

charge pressure control BJC

BR394
394

charge pressure control BJC BR394

394

Principle charge pressure

394

Turbocharger variable (VTG)

394

Volkswagen BJC engine

changing the guide vane angle

394

Volkswagen BJC engine

394

Volkswagen BJC engine

vakuum lines
394

sensors Volkswagen BJC engine

0B6 air flow mass meter

0B6
394

actuators Volkswagen BJC engine

0Y4 valve charge pressure

394

Transmission
394

Hydrostatic
394

Splitted system of hydrostatic

394

hydraulic circuit diagram

394

Transmission
394

HPV105-02
394

HPV 105-02 variable principle - feedback system

boostpressure

pilotvalve
feedback lever
2 tilt pistions

swash plate
hydrostatic bearing

21° 21°
input signal
394

HPV105-02
394

HPV105-02 flushing valve 15bar

boost pressure valve 21bar

 394

HPV105-02
Innenring-Zahnradpumpe (Triple)

retarderventil 1Y1

throttle valve 1Y10

more than 2100rpm
working hydraulic

cold start valve 1Y11

temp smaller 5°Cel.
394

Gearpump (Triple)
H40
394

Gearpump (Triple)

H45/50
394

HPV105-02
394

HPV105-02

bypass valve
towing
394

HPV105-02

brake valves

flushing unit
394

HPV105-02

high pressure
valves 425bar
394

HPV105-02
394

servopiston HPV105-02

pilot pressure
foreward/reverse.

tilt pressure

boost pressure

pilot valve

pilot pressure to tilt

valve pistons

release valve
394

Drive axle AH50-03

394

Drive axleAH50-03

rubber
planetary
bearing
ratio 1:6,67

HMF135-02 (HMF900)
394

Drive axle AH50-03

394

Drive axle AH50-03

394

Drive axle AH50-03

(HMF900)
394

Drive axle AH50-03

(HMF900)
394

Drive axle AH50-03

394

Drive axle AH50-03

HMF135-02
394

Drive axle AH50-03

HMF135-02
394

Drive axle AH50-03

GR6H-02
394

Drive axle AH50-03

394

Drive axle AH50-03

axle bearing and steer axle mounting

394

Drive axle AH50-03

rubber bearing
394

Drive axle AH50-03

rubber bearing with

extractor
394

Drive axle AH50-03

rubber bearing
with drift key
394

Steering
394

Steering
394

Steering

DBV1 120Bar
DBV2 220Bar
394

Steering

Working
Hydraulic
394

Steering

Working
Hydraulic
394

Steering
394

neutral Steering dynamic

A4 A5 A4 A5

A3 A3

A2 A2

A1
Ad
Ad

PP-bleed Dyn-bleed LS-bleed PP-bleed Dyn-bleed LS-bleed

Working Working
Engine Pump Engine Pump
Hydraulic Hydraulic
394

Working hydraulic
394

Mast series 189

394

Mast typ 189

394

Mast typ 189

mast type 189

mounting
394

Mast typ 189

mast
mounting
394

Tilt angle sensor

5° forward
9° backward
394

Control valve

mast angle preselect (SA)

394

Control valve
 394

Control valve

DBV2 Aux.
180Bar

DBV1 max. P

valve emergence lowering

394

Control valve
394

Control valve
394

Heben / Senken

Control valve

A4 B4 A3 B3 B2 A2 A1
X

DBV1
2Y7 2Y5

Vorneige n
2Y3
2Y1

` 0.8

Se nken
Rüc kneigen

DBV 2 T
180+ 5 bar

Heb en
2Y4
2Y8 2Y6 2Y2
2Y9
MP

P
394

neutral
394

neutral circuit
394

neutral circuit
2Y9 actuates
boost pressure
394

lift 2Y2 actuates

394

lift
394

lift
394

lift
DBV opens
394

lower
394

tilt pressure
394

tilt
backward
394

Controlling
394

Linde Truck Control (LTC) LTC 11

LLC LHC

Aux2 Aux1 tilt lift/lower

steering

Filter

pump 1 pump 2 pump 3

engine HPV 105 pedals

temp. rsensor
cooler

suction
filter
charge filter fan
hyd. motor hyd. motor
oiltank
 394

- swashing
HPV ...-02 controller - engine speed Linde Controlling
- overspeeding LTC principle
- acceleration/
deceleration

relase • swashing
valve • pressure
• acceleration/
deceleration

! • engine speed
• overspeeding
• power limitation
394

Service
394

Accessibility
394

Engine
LPG
394

Volkswagen VR6 LPG engine

 394

Volkswagen VR6 LPG engine

engine model: BFH
number of cylinder: 6 in V position 15°
displacement: 3189 cm³
power: 55KW at 2600 U/min
compression ratio: 11,25
compression: 10 -13 bar
wear limit: 7,5bar
max. differenc in pressure: 3bar
lower idle: 1000
upper idle: 2800
drive idle: 2700
rated speed: 1900 max. 225Nm
overspeed:
valve clearance: hydro self adjusting 4 valve per cylinder
ignition control: over maintenance free chain and two
adjustable camshaft for inlet and outlet
ignition: electronic firing order
ignition timing: 19° NU 24 ° NO
394

Volkswagen VR6 LPG engine

firing order: 1-5-3-6-2-4

oil pressure
on 1000U/min: min. 2bar
on 2000U/min: min. 3 - 4,5bar
cylinder 1 opposite flywheel side
spark plug: NGK 12KR7B 1.1mm

engine oil: approx. 6,6 l

change oil approx. 6l
thermostat: 80°C start 105°C fully open

Impco LPG system : electronic cut-off valve with filter

varporiser Cobra as BR392
mixer as BR 352 CA100
394

Volkswagen VR6 LPG engine

394

Volkswagen VR6
LPG engine

flat belt

alternator

air condition
394

Volkswagen VR6 LPG engine

engine speed sensor

engine oil filter

 394
Ventildeckel

Volkswagen VR6 LPG engine

inlet camshaft
outlet camshaft

camshaft adjustment
394

Volkswagen VR6 LPG engine

394

Volkswagen VR6 LPG engine

coolant pump after running 0M1

394

Volkswagen VR6 LPG engine

varporiser on catalytic
converter
394

Volkswagen VR6 LPG engine

flange for starter

coupling for travelpump

394

Volkswagen VR6 LPG engine

spark plugs
394

Volkswagen VR6 LPG engine

cylinderhead

outlet camshaft

camshaft
adjustment

inlet cam shaft

394

Volkswagen VR6 LPG engine

chain for inlet and outlet camshaft

394

Volkswagen VR6 LPG engine

roller lever
394

Volkswagen VR6 LPG engine

394

Volkswagen VR6 LPG engine

394

Volkswagen VR6 LPG engine

394

Supplements
for 392/393/394
394

392/393/394
 394

part nr. 3934709500

Aux.hyd. BR393 pressureless unit 3938082000
3938020203
1,000
1,000
Montagezeichnung 'Druckspeicher Drucklos
Schaltplan 'BR393;H25-H35 D/T
0009821006 1,000 Druckspeicher
0009525152 1,000 Rückschlagventil '0,2 bar
0009510257 1,000 Stutzen
3934308201 1,000 Zsb Halter
3934414002 1,000 Rohr 'Zsb.
3934413207 1,000 Schlauchleitung
0009552255 1,000 Halterungsschelle 'D1-18x20W1-1
0009307026 1,000 Zsb Winkel
0009502290 1,000 Zsb Rohrschelle
9008311183 2,000 Sechskantschraube 'M8x25-8.8-A2C
394

oilbath filter
394

higher version 393

394

Higher version 393

standard version higher version

point of eyes:
- 420mm higher
- 115mm more back
394

Indoor (USA) Truck H25T CT-Version

394

Indoor (USA) Truck H25T CT-Version

modified components
• rear cover
• counter weight
• muffler
• rear grill
• steer axle + hoses
• wheel hub + wheels
394

Seat to swing
394

Modified tilt cylinder 392/393

Version 1
M20x1,5 185/188
394

Modified tilt cylinder 392/393

M27x2 Version 2
185/188
394

LPG adjustment power 392/393

adjustment
BR 392/393
 394

Catalytic converter with Lambda control in BR 392/393 and 394

Why did we install an lambda control system ?

With correct mixture of the LPG and oxygen we got a optimal

combustion inside the engine. And so a reduction of pollution.
In particular the nitrogen oxides (NO,Nox, )

The carbon monoxide (CO) is not reduced.

 394
Zu finden in Service Mappe
Katalysator mit Lambda-Regelung
(Sonderunterlagen)

Catalytic converter
catyliser
Possiblitys to change LPG emission
= Greek:
Chemistry/material release a chemical The pollutants can be improved on on three
reaction! Different possions of the engine:
We distinguish in:

1) Catalytic converter with open loop 1) In the gas mixer before combustion.
(in all LPG trucks)
Emission treatment after combustion in the 2) Combustion chamber
engine (outlet side)
(way how we take in the gas)
2) Catyliser with closed loop
Emmision control at producing the LPG / air 3) Subsequent treatment in the exhaust system
mixture. Befor combustion in the LPG mixer
and Emission treatment after combustion in
the engine (outlet side)

FK2/Scheibler
394

Properties of the pollutants:

The principal emission components are nitrogen, carbon
dioxide and water steam. These components are non-
Catalytic converter toxic.

The noxious part is about one per cent and consists of

carbon monoxide, oxides of nitrogen and hydrocarbones.

1) Carbon monoxide(CO)
 colourless and odorless gas
 leads to an intoxication of the body

2) Nitrogen oxides (NO, NOx)

NO
 Colourless gas which oxygenates to NO2 when it comes
into cantact with air
 very toxic
 quick central symptom of paralysis
NO2
 redbrown gas of acrid, pungent smell
 lung irritation
 smog constitutent under influence of sunlight

3) Hydrocarbones (HC)
 almost odorless
 narcotic effect with light irritation of mucous membrane
 neurotoxin
 ear and nose irritation even in very low concentrations
394

Catalytic converter
What is new with reference to the BR 351
The control unit is learning all the time !

So there is no adjustment necessary!

Not on the LPG - mixer or the firing point.

The control unit got a signal about engine load from an temperatur
and pressure sensor in the inlet pipe.

The pressure modification valve is responsible for the gas / air mixture.
This valve open and close with an PWM Signal from the control unit .
(No step motor)

four ignition coils in one unit

The mixer have no throotle sensor. So the mixer for Lambda control
have a different part number as in the uncontroled system.
394

Catalytic converter
Variable Venturi Mixer

LINDE 392/393/394 open loop system

Air Filter

Filter
Fuel Lock TPS
Regulator

Vaporizer

Actuator
LINDE
Liquid
.
Withdrawal
Coil [4]
LPG
Container 2-Way
Catalytic
Ignition
timing Converter

Engine speed

TPS
Ignition Engine position signal
Sensor [hall]
394

Catalytic converter
LINDE 392/393/394 Variable Venturi Mixer
Pressure Modulation Valve
feedback system

Air Filter

Filter
cut off valve
Regulator
Vaporizer

Engine
PWM signal speed
Liquid solenoid
H2O
Withdrawal Pressure and temp sens.
LPG
Container coils 3-Way
Oxygen sensor
signal Ignition Catalytic
timing Converter
MIL

Engine speed

PC
PC Interface Engine Coolant temp.
ECM position
Sensor [hall]
394

Catalytic converter
minor low
pressure
from air inlet
after throttle

Ignition coil

large low
pressure before
throttle
394

Catalytic converter

filter with
cut-off valve

vaporiser
394

Catalytic converter
pressure modification valve
394

Catalytic converter

air intake
mixer

solenoid
LPG
intake
394

Catalytic converter

mixer

cap - no throttle
sensor as on all
open loop 39X

temperature and
pressure sensor
394

Catalytic converter

ignition coil
4 coils on one
unit
394

Catalytic converter

The control unit is learning all the time !

So there is no adjustment necessary!

Not on the LPG - mixer or the firing point.
 394

Catalytic converter

Diagnostic software for lambda control

The Software EDIS ECI must be installed on the PC (Laptop).

Also you need the diagnostic cable 300 365 25 04.

The Diagnostic cable for LPG is used in the same way as the engine
diagnostic cable BR 392/393/394 on the Diagnostic port besides
the LHC control unit.

Be careful: the cable for engine diagnostic and lambda control

looks similar. Order of the pins are different!

Engine must be running while doing diagnostic !

 394

Catalytic converter

The diagnostics software: EDIS ECI

1) shows inlet temperature and pressure, the adjustment to Lambda 1.
2) shows actual faults.
3) shows a fault history who can be deleted every time.
3) have teaching module. When parts worn or defect and must be
changed a teaching is necessary.

4) For testing each single ignition coil can be switched off on

a running engine .

Diagnostic cable partno. 3003652504

394

Diagnosesoftware catalytic converter

Connection with control unit

Next page by click

on the arrow.
394

Diagnosesoftware catalytic converter

temperatur in Fahrenheit

battery voltage
394

Diagnosesoftware catalytic converter

adjustment to
Lambda 1
394

Diagnosesoftware catalytic converter

faults

The fault can be deleted Activ fault disappear

per mouse click. when fault is rewoked and
truck switched off
and on.
394

Diagnosesoftware catalytic converter

Lambda 1 control

fault
warning
light
Lambda 1:
triangle moving
between Rich
and Lean
394

Diagnosesoftware catalytic converter

When parts worn or defect and must be changed a teaching is

necessary.
All in the control unit stored parameter must be deleted.
Sequence:
1) Fit new part

2) The switch „Closed - Loop Switch“ (blue) from normal to

Adjustment. Per mouse click.

3) With mouse click on „Clear Adaptive“.

4) The switch „Closed - Loop Switch“ (blue) from Adjustment

to normal.

The triangle must move all time between rich and lean,
when function is correct.
After teaching or new start (cold) this can take some minutes.
 394

Diagnosesoftware catalytic converter

For teaching with mouse click in position: Adjustment

Storage data must

be cleared per click
 supplier.)

2. Gas system:
394 Basic adjustment:
Low idle air screw: completely closed

Full load adjustment screw: R L

    
Catalytic converter 
Basic adjustment of the ignition time and the gas system: 2.1 Magnet tension on solenoid linkage to throttle:
For the adjustment of the magnet tension, the throttle stop screw must be
turned out. The magnet tension must be 0,5-1,0 mm, by which results a
The engine must be warm for check and setting maximum opening angle of 45° at BR 392 and 60° at BR 393.

1. Ignition time: 2.2 Throttle stop screw:

1
debit: 16±2°KW before t.d.c. at low idle speed (1000±10 /min). - ignition switch off and the plug of the engine speed solenoid disconnected.
(The ignition time is passed by an electronic ignition and is prepared by the - Start engine.
supplier.) - Adjusting engine speed to 700 ±100 rpm on the stop screw.
- connect the plug of the engine speed solenoid ignition must be switched off
2. Gas system: 2.3 Check the lambda control
Basic adjustment: - connect diagnosis software (E-Controls) and start engine.
Low idle air screw: completely closed - call up service page.
- error lamp shouldn’t shine red.
Full load adjustment screw: R L - The lambda control works right, if the mixture needle, (right on the service
     page) swings about the green area.
- If the error lamp shines red, then pick out the mistake memory on the error
page and repair the mistake.

- After this delete error massage (double click on the error massage and
2.1 Magnet tension on solenoid linkage to throttle: delete all errors).
For the adjustment of the magnet tension, the throttle stop screw must be
1.1turned
Checkout. the
The magnet
mixture tension must idle
at low be 0,5-1,0 mm, by which results a
speed:
- For opening
maximum the check,
angle the
of 45°engine must
at BR 392 and be
60° warmed
at BR 393.for about 1 Min with full load, so that the catalyst gets the
necessary operation temperature.
- set idle speed: 1000±10 rpm
2.2 Throttle stop screw:
- The idle mixture is all right, if the mixture needle of the software swings about the green area and
- ignition
CO < switch
0,1 off and the plug of the engine speed solenoid disconnected.
Vol.-%.
- Start engine.
Adjusting
1.2- Check the engine
full speed
load to 700 ±100 rpm on the stop screw.
mixture:
Like at
- - connect the1.1.
plug the
of thecatalyst must
engine speed be warm.
solenoid ignition must be switched off
- The full load mixture is all right, if the mixture needle of the software swings about the green area and
2.3 CheckCOthe < 0,1 Vol.-%.
lambda control
- you must get a speed of 2750±50 rpm.
- connect diagnosis software (E-Controls) and start engine.
1.3- Sealing
call up service
wax:page.
- error lamp shouldn’t
Protect shine red. screws with sealing wax
the adjustment
- The lambda control works right, if the mixture needle, (right on the service