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September 2011

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Key Changes Since Last Milestone

Functional Block Diagram (FBD)

New Content Breakdown
Belo Horizonte Graders
All Wheel Drive Vers 2
No Change Minor Change Major Change

Cab Electrical Software Hydraulic Powertrain Attachments Chassis

Instrument Hydraulic Main

Cab Vehicle Control Engine Drawbar & Circle Rear Frame
Panel Pump

Instrument Hydraulic Main Transmission Front Frame

Steering Colum Engine Control
Panel Valve Moldboard
Tandem
Hydraulic
Engine Control Transmission Gear Pumps Hood Support
Conntrol Saddle
Control Front Axle
R.H. Side Transmission AWD Pump
Console Control AWD Control Radiator Counterweight Fuel tank
Installation
Operator AWD Motors
AWD Control Air Intake Front Scarifier Rear Hood
Platform
System
Gauges/ AWD Valves
Steps Front Dozer
Senders Exhaust Hydraulic Tank
Blade
System
Lights Hydraulic Lines
Rear Ripper
Seat

Alternator, Cylinders
Front Push
Starter, Battery Plate
HVAC
Switches
Tires & Rims

Wiring
Harnesses 3

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Software Purpose

The All Wheel Drive (AWD) Software is designed to drive the hydraulic
components of the Front Wheel Drive system of a Case 865 and 885
Grader. Graders with an AWD system equipped can achieve a higher tractive
effort at poor ground conditions than conventional Graders.

Operating Modes

There are three different operating modes:

4-WD Mode (Four Wheel Drive Mode),

AWD Mode (All Wheel Drive Mode) and

Creep Mode.

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Operation/Handling

For operating the Front Wheel Drive system there is a

keypad at the instrument board consisting of two keys
and one rotary selector.

LEDs next to the keys and the rotary selector show the
state of the Front Wheel Drive system.

The All Wheel Drive Mode can be activated and

deactivated at any speed in al gear stages.

Operating Modes

4-WD mode
(Rear Wheel
Drive Only)

The machine will be driven

by rear axle transmission
only.

The Front Wheel Drive is

deactivated and in save
state with zero tractive
effort. The front wheels are
idling.

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AWD Mode (Rear Wheel Drive + Front Wheel Drive)

The machine will be driven by rear axle transmission and additionally by front
wheels. The speed of front wheels is regulated proportionally to the speed of the
rear axle. The tractive effort of the front wheels can be adjusted with the Rotary
Selector.
The AWD Mode can be enabled by pushing AWD Key on instrument board. The
AWD LED will turn on. AWD Mode can be disabled by pushing AWD Key once
again. The AWD LED will turn off.
Activating and deactivating is possible at all almost machine (forward and
reverse) and in all gear stages (forward, reverse, neutral). Activating the AWD
Mode is not allowed at Creep Mode while the Accelerator Pedal is engaged.
The on/off status of AWD Mode will be saved after switching off ignition.
Conditions for activating AWD Mode:
AWD Key pressed
AWD system is calibrated
The AWD Mode aggressiveness can be adjusted by Rotary Selector in 16
stages. The adjusted drive behavior is displayed by a LED bar near the Rotary
Selector. The adjusted aggressiveness will be saved when AWD Mode
disengaged and while ignition off. There is a possibility to recall a predefined
aggressiveness value quickly by pushing the Rotary Selector.
At stage level 0 the speed of front wheels and rear wheels are equal. The higher
the stage of Rotary Selector the higher is the speed of the front wheels. At the
highest stage the traction effort of the Front Wheel Drive reaches its maximum.

Creep Mode (Front Wheel Drive Only)

At Creep Mode the machine is driven by front wheels only. The
driver can use the Creep Mode to achieve a very low machine
speed level at a certain engine speed. The speed of front wheels is
regulated proportionally to the Accelerator Pedal position. The ratio
between engine speed and machine speed can be adjusted by the
Rotary Selector.
Maximum speed in Creep Mode will is limited to 5 kph.
At Creep Mode the front axis of the machine shows hydrostatic
behavior. Thus, the front wheels are not idling and the speed
directly depends on the AWD pump flow rate.
The Creep Mode can be enabled by pushing the Creep Mode Key
on instrument board. The Creep Mode LED will turn on. The Creep
Mode can be disabled by pushing the Creep Mode Key once again.
The Creep Mode LED will turn off.
Conditions for activating Creep Mode:
Creep Mode Key pressed
neutral gear stage position
released accelerator pedal
released service brake
machine speed -1..+5 kph
AWD system is calibrated

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Creep Mode (Front Wheel Drive Only)

If the Creep Mode Key is pressed but one of these conditions is not true, the
Creep Mode LED will flash for 3 seconds. The current Operating Mode (4-WD
Mode or AWD Mode) will not change.
The Creep Mode will be deactivated permanently when the driver changes the
gear stage or when the motor rpm is lower than idle rpm (stalling motor). Then
the Creep Mode must be activated by the driver again by pushing the Creep
Mode Key on instrument board. The on/off status will not be saved after
switching off ignition.
Machine speed depends directly on Accelerator Pedal position. The ratio of
machine speed and pedal position can be adjusted by Rotary Selector in 16
stages that are displayed by a LED bar around the Rotary Selector. Thus
customer can adjust a higher or lower engine speed level at certain machine
speed for certain flow demands of implements.
5 kph
rotary selector
=5 There is a possibility to recall quickly a
15
Machine
predefined speed scaling value by
Speed pushing Rotary Selector. Pushing the
Rotary Selector for more than 3 seconds
0 will save the current scaling as new
0 default value
0 yPd 100 %

Creep Mode: Machine speed depending on pedal position

Features

The AWD system provides several features:

Automatic Calibration

Power Mode

Quick Drive Behavior Recall

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Automatic Calibration

Before using the Front Wheel Drive system the first time a
calibration is necessary. The calibration routine compensates
production tolerances of the pump and motor solenoids. The
calibration can be started by a production worker via EST or EOL,
then it runs automatically.

Power Mode

At 865 Graders, the engine supports a higher power level if the Power Mode is
activated.

At AWD Mode the EHC engages the Power Mode at all gear stages.

At 4-WD Mode the EHC engages the Power Mode only at gear stages F7 and F8.

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Quick Drive Behavior Recall

At AWD Mode the driver can save his favorite Drive Behavior stage by
holding the Rotary Selector Button pressed for three seconds. The Rotary
Selector is confirming the new value by flashing for about three seconds.
To recall this value the driver can push the Rotary Selector Button quickly.
At Creep Mode the driver can save his favorite speed scaling value by
holding the Rotary Selector Button pressed for about three seconds. The
Rotary Selector is confirming the new value by flashing for about three
seconds. To recall this value the driver can push the Rotary Selector
Button quickly.

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COME HOME

Pump

Motor
right

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Hand
Pedal
lever
EHC

Motor
left
Transmission

Pump

Engine

Speed
Sensor

Motor
Aggressivity
right
Selector

Creep Mode AWD Mode

Key Key

PUMP HAVE A FILTER

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PUMP HAVE A FILTER

Motor
left

Pump
Flow Divider

Motor
AWD Controller
right

Flow Divider

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DIFFERENTIAL
LEFT MOLDBOARD LOCK RIGHT MOLDBOARD

DIFFERENTIAL
LOCK RIGHT MOLDBOARD

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ONLY FRONT ALL

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ACUMULATOR

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ACUMULATOR

SADDLE CONTROL RIPPER CONTROL

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SOLENOID 6,0 OHMS

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RPM SENSOR

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2 HOSES FROM FLOW DIVIDER TO WHEEL ENGINE

RETURN

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FLOW DIVIDER

RETURN
BOX

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RETURN BOX

RETURN

TO THE LEFT SIDE WHEEL ENGINE

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TO THE RIGHT SIDE WHEEL ENGINE

FROM THE
PUMP

RPM SENSOR

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Left or right? __________________

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Pilot or return? __________________

AWD pump unit

(variable displacement)

Proportional Valve MZ
(reverse direction) Proportional Valve MY
(forward direction)

Ms filter

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CONTROL DEVICE
MOVED BY FUNK TRANSMISSION

FORWARD

REVERSE

GEAR PUMP

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MECHANICAL
CONTROL

IGP

22,5 CM3 /REV

32 BAR

MAXIMUM DISPLACEMENT (CCM)

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MOVED BY FUNK TRANSMISSION

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Reverse Pressure sensor

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PILOT
LINE

RETURN BOX <PUMP

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AWD System Overview Pedal

Hand
lever

Motor
left
Transmission
Flow Divider

Tandem Pump
Engine

Speed
Sensor

Motor
Aggressivity AWD Controller
right
Selector

Creep Mode AWD Mode

Key Key

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4WD Mode Hand

Pedal
lever
Zero displacement
but all units are turning.

Transmission

no flow

Engine

No function

AWD Mode Forward Pedal

Hand
lever

Transmission

Engine

Speed
Sensor

0…15%
Aggressivity
0%: front RPM = rear RPM
Selector
15%: front RPM = rear RPM + 15%

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AWD Mode Reverse

Hand
Pedal
lever
AWD Controller

Transmission

Engine

Speed
Sensor

0…15%
Aggressivity
0%: front RPM = rear RPM
Selector
15%: front RPM = rear RPM + 15%

Creep Mode (Forward only)

Hand
Pedal
lever

Transmission

There is no rear wheel drive.

Rear wheels are freewheeling.
Engine

Speed
Sensor
5 kph
ratio selector
=5
15
vehicle
speed Ratio engine RPM
ratio:
Selector vehicle speed
0

0
0 pedal stroke 100 %

800 engine RPM 2200 rpm

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Hydraulic Overview

Pump Hydraulics
AWD pump unit
(variable displacement)

Pressure sensors
(both driving directions)
Motor pilot supply

Charge pump
(pilot supply)
Mz=Proportional Valve
(reverse direction) My=Proportional Valve
(forward direction)

Ms=Pilot dump valve

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Motor Hydraulics
Wheel reducer (increased wheel torque)

Speed sensor left

Proportional valve
(control motor displacement)
AWD motor unit
(variable displacement)

Flow Divider
High pressure from pump
Pilot supply from pump
High pressure return line to pump

Speed sensor left

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AWD controller inputs and

outputs
Input Output

Pin #

Pin #
Description Description
Type Type

Pump pilot valve 59 DOUT

Ignition Key 18 DIN Pump reverse 10 PWM (c.c.)

17 DIN
Break Switch Pump forward PWM (c.c.)
19 DIN 48
34 FIN (0°) Motor left 57 PWM (c.c.)
Speed sensor right 35 FIN (90°)
Motor right 4 PWM (c.c.)
32 CIN (Sense)
36 FIN (0°) Diagnosis messages CAN 1s cycle time
Speed sensor left 37 FIN (90°)
40 CIN (Sense)

Pressure sensor reverse 7 CIN

Pressure sensor forward 6 CIN
12 DIN
Accelerator Pedal
13 DIN
Machine rear speed 34 FIN
14 DIN
Gear stage lever 15 DIN
16 DIN
AWD Mode switch CAN 100ms
Creep Modeswich CAN 100ms
Drive Behavior CAN 100ms
Accelerator Pedal position CAN 10ms CAN value
Diesel engine rpm CAN 10ms
Shaft speed CAN 100ms
Gear Stage CAN 10ms

•Drive Preference Recall

AWD Features
• At AWD Mode the driver can save his favorite Drive Behavior stage
by holding the Rotary Selector Button pressed for three seconds.
• The Rotary Selector is confirming the new value by flashing for
about three seconds.
• To recall this value the driver can push the Rotary Selector Button
quickly.
• At Creep Mode the driver can save his favorite speed scaling value
by holding the Rotary Selector Button pressed for about three
seconds.
• The Rotary Selector is confirming the new value by flashing for
about three seconds.
• To recall this value the driver can push the Rotary Selector Button
quickly.
•Last setting will be saved after switching off AWD and re-activated
after switching on AWD
•Default – when the operator turns off the machine, the unit will
restart in AWD mode

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AWD Features
• Automatic Calibration

• Before using the Front Wheel Drive system the first time a calibration is
necessary.
• The calibration routine compensates production tolerances of the pump and
motor solenoids.
• The calibration can be started by a production worker via Engineering Service
Tool (EST) , then the calibration routine runs automatically, then the calibration
complete message is given “ Calibration successfully complete “.

• All machines leaving the plant are already calibrated.

• Recalibration is needed only when the AWD components are changed such as Pump,
Hydraulic Motor.
• When Change tires size no calibration is needed. But the configuration has to be changed
via EST.
•Transmission changed out does not require AWD recalibration.

Error Codes Trouble shooting

:
5329 K ECU: Gear stage and gear selector position do not match.

5331 EV-MS: Open circuit at pilot dump valve of AWD pump.

5332 EV-MS: Short circuit to ground at pilot dump valve of AWD pump.
5333 EV-MS: Short circuit to power at pilot dump valve of AWD pump.

5341 EV-MY: Open circuit at pilot valve on forward direction of AWD pump.
5342 EV-MY: Short circuit to ground at pilot valve on forward direction of AWD pump.
5343 EV-MY: Short circuit to power at pilot valve on forward direction of AWD pump.
5344 EV-MY: Wrong current level at pilot valve on forward direction of AWD pump.
5347 AWD: Control software failure at pilot valve on forward direction of AWD pump.

5351 EV-MZ: Open circuit at pilot valve on reverse direction of AWD pump.
5352 EV-MZ: Short circuit to ground at pilot valve on reverse direction of AWD pump.
5353 EV-MZ: Short circuit to power at pilot valve on reverse direction of AWD pump.
:

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AWD System Overview Pedal

Hand
lever
EHC

Motor
left
Transmission

Pump

Engine

Speed
Sensor

Motor
Aggressivity
right
Selector

Creep Mode AWD Mode

Key Key

Grader Front Wheel Drive (FWD) – Functional Scheme 885 B

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Flo

IN NEUTRAL THE
PRESSURE
CHARGE GOES
TO TANK

Proportional Proportional
valve(reverse valve(forward
direction) direction)

Mz Ms My

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FORWARD

WHAT DO THE PRESSURE CHARGE AT

THE ENGINE?

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Wheel reducer

Foto do painel apagada

Foto 1500 rpm durante

calibração

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MOTOR

MOTOR

PUMP

Calibration time = 3,5 min.

RPM = 850 RPM

1.501 RPM

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CREP MODE KEY OFF SMALL VARIATION

MÁX. RPM and VELOCITY = O

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CREP AWD
MODE MODE

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