Product Manual
B200 series
Contents
1 General Instructions......................................................................... 4
1.1 About the manual............................................................................................................................................4
1.2 Intended use.....................................................................................................................................................4
1.3 Warranty.............................................................................................................................................................4
1.4 Product identication..................................................................................................................................... 4
1.5 Publication date............................................................................................................................................... 5
1.6 Declaration of incorporation......................................................................................................................... 5
2 Safety Instructions...........................................................................6
2.1 Warning symbols..............................................................................................................................................6
3 Motor Description..............................................................................7
3.1 Working principle.............................................................................................................................................. 7
3.2 Product identication code...........................................................................................................................8
3.2.1 Motor model code B200 series..................................................................................................8
3.2.2 Processing ID................................................................................................................................10
3.3 Technical data..................................................................................................................................................11
3.4 Motor interfaces............................................................................................................................................. 13
3.4.1 Main dimensions..........................................................................................................................13
3.4.2 Shaft interface............................................................................................................................. 14
3.4.3 Hub interface................................................................................................................................15
3.4.4 Housing interface........................................................................................................................16
3.4.5 Secondary housing interface...................................................................................................18
3.4.6 Drum brake interface..................................................................................................................19
3.4.7 Hydraulic connections...............................................................................................................20
3.5 Rotating direction..........................................................................................................................................20
3.6 1-speed : 1N0xx.............................................................................................................................................. 21
3.7 2-speed valve : 2NRxx / 2NLxx.................................................................................................................. 21
3.8 Freewheeling valve in: FW11x / FW21x .................................................................................................... 23
3.9 Freewheeling.................................................................................................................................................. 24
3.9.1 Hydrostatic freewheeling......................................................................................................... 24
3.9.2 Mechanical freewheeling..........................................................................................................25
3.10 Speed sensor..................................................................................................................................................26
3.11 Seal protector.................................................................................................................................................28
3.11.1 Fittings for one-time lubrication.............................................................................................28
3.11.2 Fittings for regular lubrication.................................................................................................29
3.12 Drum brake..................................................................................................................................................... 30
3.12.1 2015/68 ECE R13........................................................................................................................ 30
3.13 Accessories......................................................................................................................................................31
3.13.1 Disc brake...................................................................................................................................... 31
3.13.2 Stud bolts......................................................................................................................................33
4 System Design................................................................................. 34
4.1 Motor hydraulic circuit................................................................................................................................. 34
4.1.1 Simple connection......................................................................................................................34
4.1.2 Motors in parallel or series circuit...........................................................................................34
4.1.3 Counter pressure operation..................................................................................................... 36
4.1.4 Hydrostatic braking....................................................................................................................36
4.1.5 Short circuit operation...............................................................................................................36
Contents
2 Product Manual
4.2 Hydraulic connections..................................................................................................................................37
4.3 External freewheeling valve........................................................................................................................37
4.4 Hydraulic uid................................................................................................................................................ 39
4.4.1 Hydraulic uid type.................................................................................................................... 39
4.4.2 Hydraulic uid properties..........................................................................................................39
4.4.3 Hydraulic uid cleanliness........................................................................................................39
4.5 Operating pressures..................................................................................................................................... 39
4.5.1 Case pressure..............................................................................................................................39
4.5.2 Pilot pressure...............................................................................................................................40
4.5.3 Working line pressure.................................................................................................................40
5 Motor Sizing..................................................................................... 43
5.1 Load carrying capacity................................................................................................................................ 43
5.1.1 Wheel oset..................................................................................................................................43
5.1.2 Allowed wheel load.................................................................................................................... 44
5.1.3 Service life.................................................................................................................................... 45
5.1.4 Axial load capacity......................................................................................................................46
5.2 Performance...................................................................................................................................................46
5.2.1 Rotating speed and ow rate.................................................................................................. 46
5.2.2 Torque............................................................................................................................................ 47
5.2.3 Power.............................................................................................................................................48
5.3 Performance charts......................................................................................................................................48
5.3.1 B240 motors performance curves.........................................................................................48
5.3.2 B250 motors performance curves.........................................................................................50
5.3.3 B260 motors performance curves..........................................................................................51
5.3.4 B270 motors performance curves......................................................................................... 53
5.4 B200 motors case leakage......................................................................................................................... 54
6 Installation Instructions................................................................ 55
6.1 Mounting the motor......................................................................................................................................55
6.2 Flushing the hydraulic system...................................................................................................................55
6.3 Air bleeding procedure.................................................................................................................................55
6.4 Commissioning procedure..........................................................................................................................56
7 Operating Instructions................................................................... 57
7.1 Break-in period...............................................................................................................................................57
7.2 Use.....................................................................................................................................................................57
7.3 Operating temperature.................................................................................................................................57
7.4 Demounting the motor.................................................................................................................................57
8 Special Instructions........................................................................59
8.1 Storing the motor.......................................................................................................................................... 59
Contents
Product Manual 3
General Instructions
About the manual
This manual contains the technical instructions for the Black Bruin B200 series
hydraulic motors. Take these instructions into consideration when planning the use
of the product.
All information given in this manual is current and valid according to the information
available at the time of publication. The manufacturer reserves the rights to
implement changes without prior notice.
Please visit www.blackbruin.com for the most recent version of this manual. The
product datasheets and the 3D-models are available from the manufacturer by
request.
Intended use
Black Bruin B200 series hydraulic motors are designed to be used as hub motors
on vehicles. They can also be used in other applications that need torque for rotary
movement.
Warranty
Check the package and the product for transport damage when receiving goods. The
package is not meant for long term storage; protect the product appropriately.
Do not dismantle the product. The warranty is void if the product has been
disassembled.
The manufacturer is not responsible for damages resulting from misinterpreted,
non-compliance, incorrect, or improper use of the product that goes against the
instructions given in this document.
Product
identication
The product identication data can be found on the identication plate attached to
the motor.
Figure 1. Identication plate of the motor.
1. Serial number
2. Part number
3. Model
4. Maximum allowed operating pressure
Note:
The serial number is also stamped on the motor. All manufacturing data
can be found with the serial number.
1
1.1
1.2
1.3
1.4
General Instructions
4 Product Manual
Publication date
06.11.2023 - This manual is published.
Declaration of incorporation
1.5
1.6
General Instructions
Product Manual 5
Safety Instructions
The following instructions apply to all procedures associated with the motor. Read
these instructions carefully and follow them closely.
• Use necessary personal protective equipment when working with the motor.
• Support the motor properly. Make sure the motor cannot fall over or turn around
by accident.
• Use only appropriate equipment and attachments for lifting and transferring the
motor.
• Do not use magnetic lifting devices.
• Always use the lifting equipment properly and check the load-bearing capacity.
• Prevent unintended use of the motor during installation and maintenance
procedures by preventing pressurization of the hydraulic lines.
• The operating temperature of the motor may be over 60 ºC (140 °F), which is hot
enough to cause severe burns. Beware of hot hydraulic uid when disconnecting
the hydraulic connections.
Warning symbols
The following symbols are used in this manual:
Note:
Useful information.
Danger:
Danger of death or injury.
Attention:
May cause damage to the product.
2
2.1
Safety Instructions
6 Product Manual
Motor Description
Working principle
B200 series motors are rotary-housing. This means the motor shaft and the cylinder
block remain in place while the motor is running.
Figure 2. The main components of the motor.
1. Shaft
2. Distribution valve
3. Cylinder block
4. Piston
5. Cam roll
6. Cam ring
7. Bearings
8. Housing
9. Hub
10. Shaft sealing
The rotation of the motor is achieved by feeding pressurized hydraulic uid through
the motor shaft to the distribution valve. The distribution valve directs the ow to
the pistons which are on a power stroke. Pressure pushes the pistons and cam
rolls outwards against the cam ring on the housing. The waveform of the cam ring
transforms the force into torque. When the pistons reach the end of the power stroke,
the distribution valve closes the ow to the pistons and switches the pistons to a
return stroke. The cam ring pushes the pistons back into the cylinder block preparing
them for the next power stroke.
Figure 3. Flow to and from the pistons.
Figure 4. Cylinder block, cam ring and pis-
tons.
3
3.1
Motor Description
Product Manual 7
Product identication code
Black Bruin product identication code consists of motor model code and processing
ID.
B200 SERIES PRODUCT IDENTIFICATION CODE
B260-0250-2NL00 / GZ - 1 1 0 0 0 0
Motor model code - Processing ID
Motor model code B200 series
B200 SERIES MODEL CODE AAAA - BBBB - CCCCC / D
Hub motors
A: Frame AAAA -BBBB-CCCCC/D B240 B250 B260 B270
B200 series frames
B240 ●
B250 ●
B260 ●
B270 ●
B: Displacement AAAA-BBBB-CCCCC/D B240 B250 B260 B270
B240 displacements 0050 : 500 ccm/rev ●
0063 : 630 ccm/rev ●
0080 : 800 ccm/rev ●
B250 displacements
0100 : 1000 ccm/rev ●
0125 : 1250 ccm/rev ●
0160 : 1600 ccm/rev ●
B260 displacements
0200 : 2000 ccm/rev ●
0250 : 2500 ccm/rev ●
0315 : 3150 ccm/rev ●
B270 displacements
0400 : 4000 ccm/rev ●
0500 : 5000 ccm/rev ●
0630 : 6300 ccm/rev ●
C: Displacement control AAAA-BBBB-CCCCC/D B240 B250 B260 B270
1-speed: CCCxx 1N0xx : Fixed displacement ● ● ● ●
2-speed valve: CCCxx
2NRxx : Right side - CW prefer-
red
● ● ● ●
2NLxx : Left side - CCW prefer-
red
● ● ● ●
Freewheeling valve: CCCCx
FW11x* : Type 1 - Open free-
wheeling position
● ● ● ●
FW21x* : Type 2 - Closed free-
wheeling position
● ● ● ●
Freewheeling: xxxCx
xxx0x : Hydrostatic freewheel-
ing
● ● ● ●
3.2
3.2.1
Motor Description
8 Product Manual
C: Displacement control AAAA-BBBB-CCCCC/D B240 B250 B260 B270
xxx1x : Mechanical freewheeling ● ● ● ●
Speed sensor xxxxC
xxxx0 : No speed sensor or
speed sensor readiness
● ● ● ●
xxxx1 : Speed sensor ● ● ● ●
xxxx2 : Speed sensor readiness ● ● ● ●
D: Accessory AAAA-BBBB-CCCCC/D B240 B250 B260 B270
Seal protection
NZ : Fittings for one-time lubri-
cation
● ● ● ●
GZ : Fittings for regular lubrica-
tion
● ● ● ●
Drum brake**
MRJ40-0-086-2 : Brake size
320x75, BRM
●
MRJ50-0-100-2 : Brake size
400x80, BRM
●
MRJ50-0-150-2 : Brake size
400x80, BRM
●
MRJ50-0-100-3 : Brake size
400x80, BRA
●
MRJ50-0-150-3 : Brake size
400x80, BRA
●
MRJ61-R-161-3 : Brake size
420x180, right side, BRA
●
MRJ61-L-161-3 : Brake size
420x180, left side, BRA
●
MRJ61-R-529-3 : Brake size
420x180, right side, BRA
●
MRJ61-L-529-3 : Brake size
420x180, left side, BRA
●
MRJ61-R-646-3 : Brake size
420x180, right side, BRA
●
MRJ61-L-646-3 : Brake size
420x180, left side, BRA
●
* = Always with mechanical freewheeling
** = Certied brakes, manufactured by Monroc.
More detailed information and mounting dimensions for each brake device can be found
on the product datasheet.
The drum brake increases the length of the motor assembly and aects the oset value of
the vehicle wheel rim.
Adding lubricant into the seal protector is prevented.
Code example B260 - 0250 - 2NL10 / GZ
A - B - C / D
A = The frame of the motor is "B260".
B = The displacement of the motor is 2500 ccm/rev.
Motor Description
Product Manual 9
Code example B260 - 0250 - 2NL10 / GZ
C =
Internal 2-speed valve for displacement control. The motor is CCW preferred in 2-speed mode.
Mechanical freewheeling. No speed sensor (speed sensor cannot be retrotted).
D = The motor seal protector is tted for regular lubrication.
Processing ID
B200 SERIES PROCESSING ID R M S P D T
R M S P D T Lubrication Denition of factory lubrication
0 = Seal protector is not lled with lubricant.
1)
1 = Seal protector is lled with lubricant.
R M S P D T Painting Denition of the painted surfaces
0 = No painting - Motors are protected from corrosion.
1 = Painting type 1 - Unpainted interfaces: SHAFT, HUB
2)
2 = Painting type 2 - Unpainted interfaces: SHAFT, HUB, HOUSING
2)
R M S P D T Protection
Denition of the protection for storage/trans-
portation
0 = Default / Not dened
3)
R M S P D T Packaging Denition of the motor package
0 = Default / Not dened
4)
R M S P D T Documents
Denition of the printouts to be attached to the
delivery
0 = Default / Not dened
R M S P D T Testing Denition of the testing and reporting
0 = Default / Not dened
5)
Code example 1 1 0 0 0 0
R M S P D T
R = The seal protector of the motor is lled with lubricant.
M = Prime coating. The shaft and hub interfaces of the motor are unpainted.
S =
Pressure openings and threaded holes of the motor are protected according to
general practices of the manufacturer.
P = The motor is packaged according to general practices of the manufacturer.
D =
The documentation delivered with the motor is according to general practices of
the manufacturer.
T = The motor is tested according to general practices of the manufacturer.
3.2.2
Motor Description
10 Product Manual
1)
It is recommended to ll the seal protector with lubricant for longer sealing
lifetime but, if necessary, the seal protector can stay unlled.
2)
Prime coating: Black, paint thickness >80 µm.
3)
Pressure openings and threaded holes are capped with plastic ttings. Hydraulic
uid is drained out.
4)
Delivery on wooden pellet or in plywood box.
5)
The manufacturer keeps test records of every manufactured motor.
Technical data
TECHNICAL DATA B240 B250
Displacement [ccm]
at full displacement 500 630 800 1000 1250 1600
at partial displacement 250 315 400 500 625 800
Maximum torque [Nm]
theoretical 2790 3510 4460 5570 6960 8910
with 100 bar 796 1000 1270 1590 1990 2550
Max. operating power [kW]
at full displacement 35 50
at partial displacement 21 30
Max. rotating speed [rpm]
at full displacement 300 240 185 200 160 125
at partial displacement 450 360 275 300 240 185
at freewheeling 600 500
Min. rotating speed [rpm] 2 2
Max. engaging speed (out of freewheel-
ing) [rpm]
148 120 93 100 80 63
Drum brake torque [Nm]
1)
8600 13500
Max. working pressure [bar]
peak pressure 350 350
intermittent
2)
300 300
Max. case pressure [bar]
average 2 2
intermittent
2)
10 10
Pilot pressure for internal valve [bar]
valve released 0-2 0-2
valve engaged 15-30
3)
15-30
3)
Max. ow rate [l/min]
at full displacement 150 200
at partial displacement 113 150
Max. load capacity [t]
4)
4,0 5,4
Weight [kg] no brake 59 92
3.3
Motor Description
Product Manual 11
TECHNICAL DATA B240 B250
with drum brake 96 156
TECHNICAL DATA B260 B270
Displacement [ccm]
at full displacement 2000 2500 3150 4000 5000 6300
at partial displacement 1000 1250 1575 2000 2500 3150
Maximum torque [Nm]
theoretical 14300 17900 22600 28600 35800 45100
with 100 bar 3180 3980 5010 6370 7960 10000
Max. operating power [kW]
at full displacement 90 130
at partial displacement 54 80
Max. rotating speed [rpm]
at full displacement 175 140 110 125 100 80
at partial displacement 225 180 145 160 130 105
at freewheeling 400 350
Min. rotating speed [rpm] 2 2
Max. engaging speed (out of freewheel-
ing) [rpm]
88 70 55 63 35 40
Drum brake torque [Nm]
1)
20100 -
Max. working pressure [bar]
peak pressure 450 450
intermittent
2)
400 400
Max. case pressure [bar]
average 2 2
intermittent
2)
10 10
Pilot pressure for internal valve [bar]
valve released 0-2 0-2
valve engaged 15-30
3)
15-30
3)
Max. ow rate [l/min]
at full displacement 350 500
at partial displacement 225 325
Max. load capacity [t]
4)
12,5 15,4
Weight [kg]
no brake 150 285
with drum brake 262 -
1)
The braking torque is for information only. Braking performance should be
ensured by testing and / or certication.
2)
Intermittent operation: permissible values for maximum of 10% of every minute.
3)
If pilot pressure over 30 bar is used, the pilot line should be throttled.
4)
The load capacity must be estimated for every application.
Motor Description
12 Product Manual
Motor interfaces
Main dimensions
Figure 5. Main dimensions of the motor.
MAIN DIMENSIONS
B240 B250 B260 B270
Motor
L1 [mm] 262 279 317 377
L2 [mm] 163 177 204 262
D1 [mm] 278 342 408 512
3.4
3.4.1
Motor Description
Product Manual 13
Shaft interface
Figure 6. Dimensions of the shaft interface.
INTERFACE DIMENSIONS
B240 B250 B260 B270
Shaft interface
D2 [mm] 140 175 200 260
pattern 6x60° 8x45° 12x30° 16x22,5°
size M16x2,0 M16x2,0 M20x1,5 M20x1,5
strength class
1)
12,9 12,9 12,9 12,9
tightening tor-
que
2)
[Nm]
330 330 650 650
D3 min.
3)
[mm] 114 150 170 220
D4 min.
4)
[mm] 165 200 240 300
R1 max. [mm] 1 1 1 1
C1 [mm] 4-10 4-10 4-10 4-10
1)
Strength class as in ISO898-1. If using lower strength class, check interface load
capacity and tightening torque.
2)
Declared values are for reference only. Always use application specic
tightening torques when given.
3)
Free space for hydraulic connections.
4)
Recommended feature to support and center the motor.
3.4.2
Motor Description
14 Product Manual
The motor is attached to the body of the vehicle or device from the shaft ange.
The hydraulic connections of the motor are located on the plane surface of the shaft
ange.
Hub interface
Figure 7. Dimensions of the hub interface.
INTERFACE DIMENSIONS
B240 B250 B260 B270
Hub interface
D5 [mm] 205 275 335 425
pattern 6x60° 8x45° 10x36° 12x30°
size M18x1,5 M20x1,5 M22x1,5 M22x1,5
strength class
1)
10,9 10,9 10,9 10,9
tightening tor-
que
2)
[Nm]
383 540 728 728
D6 min. [mm] 161 221 281 371
V1 min. [mm] 1x45° 1x45° 1x45° 1x45°
D7 min. [mm] 255 325 390 470
1)
Strength class as in ISO898-1. If using lower strength class, check interface load
capacity and tightening torque.
3.4.3
Motor Description
Product Manual 15
2)
Declared values are for reference only. Always use application specic
tightening torques when given.
The wheel rim or the rotatable device is attached to the motor hub.
Note:
The attachment screws are not included in the motor delivery. Ensure
correct dimensioning and availability of the hub screws.
There are multiple dierent types of fastening screws for hub interface.
Select the hub screws according to the wheel rim design.
Figure 8. Hub fastening screw variants.
Housing interface
Figure 9. Dimensions of the housing interface.
3.4.4
Motor Description
16 Product Manual
INTERFACE DIMENSIONS B240 B250 B260 B270
Housing interface
D8 [mm] 204 236 274 330
pattern 12x30° 12x30° 18x20° 18x20°
size M10x1,5 M12x1,75 M12x1,75 M16x2,0
strength class
1)
10,9 10,9 10,9 10,9
tightening tor-
que
2)
[Nm]
64 110 110 275
D9 min. [mm] 184 205 254 302
V2 min. [mm] 1x45° 1x45° 1x45° 1x45°
1)
Strength class as in ISO898-1. If using lower strength class, check interface load
capacity and tightening torque.
2)
Declared values are for reference only. Always use application specic
tightening torques when given.
The necessary accessories can be attached to the housing interface. The interface
can be used, for example, to attach a brake disc of a disc brake.
Figure 10. The motor with a disc brake.
Note:
If necessary, the grease nipples and plugs of the seal protector can be
removed temporarily when attaching accessories to the housing interface.
Note:
Surface roughness (Ra) of the counterparts must be 12,5μm or better.
More detailed interface dimensions and tolerances are indicated on the
product datasheet.
Motor Description
Product Manual 17
Secondary housing interface
ØB
ØA
Figure 11. Dimensions of the secondary housing interface.
INTERFACE DIMENSIONS
B240 B250 B260 B270
Secondary housing interface
ØA min. [mm] 234 290 350 445
ØB [mm] 255 313 380 478
pattern 12x30° 12x30° 20x18° 24x15°
size M10x1,5 M12x1,75 M12x1,75 M16x2,0
strength class
1)
12,9 12,9 12,9 12,9
tightening tor-
que
2)
[Nm]
77 135 135 330
1)
Strength class as in ISO898-1. If using lower strength class, check interface load
capacity and tightening torque.
2)
Declared values are for reference only. Always use application specic
tightening torques when given.
3.4.5
Motor Description
18 Product Manual
Drum brake interface
Figure 12. Interface dimensions of the motor with the drum brake (B240, B250).
Figure 13. Interface dimensions of the motor with the drum brake (B260).
INTERFACE DIMENSIONS
B240 B250 B260
Drum brake interface
L3 [mm] 277 295 451
D10 [mm] 349 444 460
D11 [mm] 140 175 200
pattern 6x60° 8x45° 12x30°
size M16x2,0 M16x2,0 M20x1,5
strength class
1)
12,9 12,9 12,9
3.4.6
Motor Description
Product Manual 19
INTERFACE DIMENSIONS B240 B250 B260
tightening tor-
que
2)
[Nm]
330 330 650
D12 [mm] max. 121 max. 156 min. 235,5
C2 [mm] 4,5 4,5 4,5
V3 min. [mm] 1x45° 1x45° 1x45°
R2 max. [mm] 1 1 1
D13 [mm] 114 150 170
1)
Strength class as in ISO898-1. If using lower strength class, check interface load
capacity and tightening torque.
2)
Declared values are for reference only. Always use application specic
tightening torques when given.
Hydraulic connections
Work ports A/B Pilot port Y Pilot port F Drain line C
B240
G3/4"
G1/2" G1/4" G3/8"
G1/2" (2-speed model)
B250 G3/4" & SAE 1" G3/4" G1/4" G3/8" & SAE 1/2"
B260
G1" (in 1-speed also SAE 1
1/4")
G3/4" G1/4" G3/4"
B270 G1" & SAE 1 1/4" G3/4" G1/4" G3/4" & SAE 1"
Rotating direction
Figure 14. Rotating direction of the motor.
The rotating direction of the motor is dened as the rotating direction of the housing
viewed from the hub to the shaft.
The rotating direction of the motor and the ow direction in the working lines is given
in the table below.
3.4.7
3.5
Motor Description
20 Product Manual
Table 1: Rotating direction and ow direction.
ROTATING DIRECTION
ow direction
A → B B → A
1N0xx, FW11x, FW21x CW CCW
2NRxx CW CCW
2NLxx CCW CW
Preferred operating direction
AAAA - BBBB - 2NRxx / D
AAAA - BBBB - 2NLxx / D
The preferred operating direction applies to motors with 2-speed valve (see 3.7 2-
speed valve : 2NRxx / 2NLxx).
The preferred operating direction is the rotating direction of the motor when the ow
direction is from port A to B.
• 2NRxx = CW motor (For the right side of a vehicle.)
•
2NLxx = CCW motor (For the left side of a vehicle.)
1-speed : 1N0xx
AAAA - BBBB - 1N0xx / D
Displacement control selection 1-speed means the motor has a xed displacement.
These motors are known as 1-speed motors and are always in full displacement
during operation.
Figure 15. 1-speed motor. Figure 16. Hydraulic circuit, 1-speed motor.
2-speed valve : 2NRxx / 2NLxx
AAAA - BBBB - 2NRxx / D
3.6
3.7
Motor Description
Product Manual 21
AAAA - BBBB - 2NLxx / D
The 2-speed valve enables change of displacement during operation. The benet
of this function is a more extensive speed range with the same hydraulic system
capacity. The motors are also known as 2-speed motors.
Figure 17. 2-speed motor.
Figure 18. Hydraulic circuit, 2-speed motor.
The change of displacement works by switching the piston to idle on every second
stroke. This is done with the in-built 2-speed valve, which changes the uid
circulation in the motor.
USING THE 2-SPEED VALVE
Using the 2-speed valve works in the same manner as gear shifting.
• SHIFTING TO HALF DISPLACEMENT
The motor is switched to half displacement by applying the pilot pressure (see
4.5.2 Pilot pressure) to the pilot line (Y).
When the motor operates at half displacement, it rotates twice as fast and
generates half of the torque when compared to a motor on full displacement with
the same ow rate and pressure.
The working pressure should be primarily applied into the working line A. The
motor operates at lower eciency and the operating temperature may rise if
working pressure is applied into the working line B.
• SHIFTING TO FULL DISPLACEMENT
The motor is switched back to full displacement by releasing the pressure in the
pilot line (Y).
When the motor operates at full displacement, it works like the 1-speed motor and
it may be operated normally on both directions.
Attention:
Take the following things into consideration, when changing the speed
range during motion.
• Hydraulic system supply must adjust to the rapid change of owrate.
Motor Description
22 Product Manual
• The rapid change in ow rate may cause momentary jerk. This may be
avoided by throttling the working lines lightly.
• Prevent operating conditions, in which the permissible performance
values could be exceeded.
The permissible performance values are in the technical data (see 3.3
Technical data).
Attention:
Continuous use of high working pressure in the working line B at half
displacement may cause premature wear or failure of the motor.
Freewheeling valve in: FW11x / FW21x
AAAA - BBBB - FW11x / D
AAAA - BBBB - FW21x / D
The freewheeling valve is used for disengaging the motor during motion (see 3.5
Rotating direction). The freewheeling valve of the motor is an alternative for the
external freewheeling valve (see 4.3 External freewheeling valve).
The freewheeling valve connects the working lines to the case drain line inside
the motor. In this way the motor can be disengaged and engaged as smoothly as
possible.
Figure 19. A motor with freewheeling valve.
Figure 20. Hydraulic circuit, a motor with
internal freewheeling valve.
FREEWHEELING VALVE TYPE
Please note that the images below also show the crossover position of the valve.
• FW11x = VALVE TYPE 1
The working lines (A and B) of the motor are open (in short circuit), when the
motor is disengaged.
3.8
Motor Description
Product Manual 23
• FW21x = VALVE TYPE 2
The working lines (A and B) of the motor are closed (plugged), when the motor is
disengaged.
Note:
The crossover position of the freewheeling valve momentarily connects
the working lines together inside the motor. This improves disengaging
and engaging of the motor, when compared to the external freewheeling
valve.
USING THE FREEWHEELING VALVE
The freewheeling valve (3) is controlled with the pilot line (F) pressure.
• ENGAGING THE MOTOR
Engage the motor by applying the pilot pressure to the pilot line (F).
When the motor is engaged, it works like the 1-speed motor.
• DISENGAGING THE MOTOR
Disengage the motor by releasing the pressure in the pilot line (F).
The orice (4) in the pilot line (F) dampens the case pressure peaks, if pilot pressure is
higher than recommended (see 4.5.2 Pilot pressure).
Freewheeling
The hydrostatic freewheeling is a standard feature in the B200 series motors.
The mechanical freewheeling is an option in the B200 series motors.
Black Bruin motors can be freewheeled without energy loss or overheating problems
(stationary cylinder block - no centrifugal forces), even at high speeds. The motors
can be re-engaged or disengaged during movement.
Hydrostatic freewheeling
Hydrostatic freewheeling requires a drain line check valve with 0.5 bar (8 psi) opening
pressure and active feed between the check valve and the drain port of the motor.
A check valve in the drain line regulates the pressure in the case. To limit the pressure
spikes in the case, the drain line and its check valve have to be sized to correspond
with the maximum ow rate at the time of engagement.
In order to create the freewheeling pressure into the case, uid must be supplied to
case drain line C between the motor and the check valve.
3.9
3.9.1
Motor Description
24 Product Manual
Mechanical freewheeling
Figure 21. A piston with the freewheeling spring.
The motor is equipped with mechanical freewheeling springs, which enable the motor
disengagement. When disengaged the motor may be used without active uid supply
from the hydraulic system.
USING THE FREEWHEELING
When the motor is depressurized and not rotating, the motor will disengage
automatically. The motor disengagement during motion is done with a freewheeling
valve.
The freewheeling valve may be in-built to the motor (see 3.8 Freewheeling valve in:
FW11x / FW21x ) or a separate external valve (see 4.3 External freewheeling valve),
which connects the working lines (A and B) and the case drain line (C) together. The
purpose of the valve is to remove pressure dierence over the motor pistons. This
allows the pistons to retract with aid of mechanical springs.
• DISENGAGING THE MOTOR
Open the freewheeling valve and depressurize the motor with the directional
control valve to disengage the motor.
• ENGAGING THE MOTOR
Close the freewheeling valve and pressurize the motor with the directional control
valve to engage the motor.
The directional control valve and the freewheeling valve are usually activated
simultaneously.
Note:
Another use of the freewheeling is a more extensive speed range for
vehicles having several hydraulic motors. Hydraulic system capacity
may be divided between fewer motors, when some of the motors are
disengaged.
Attention:
Any pressure in the working lines (A and B) during the freewheeling
pushes the pistons out of the freewheeling position. This causes a
clattering noise when the pistons hit the cam ring.
Constant clattering of the pistons may cause premature wear or failure of
the motor.
3.9.2
Motor Description
Product Manual 25
ROTATING SPEED
The rotating speed of the motor should be taken into account when implementing
freewheeling.
• FREEWHEELING SPEED
The freewheeling speed is the highest permissible rotating speed of the motor
during freewheeling.
• ENGAGING SPEED
The engaging speed is the highest permissible rotating speed when engaging the
motor.
The permissible freewheeling and engaging speeds can be found on the technical
data (see 3.3 Technical data).
DISENGAGING DELAY
While the pistons are retracting, there is a momentary ow of hydraulic uid from
the working lines to the casing of the motor. This causes always a small delay when
disengaging the motor. Normal delay is about 1 - 2 seconds.
To minimize the disengaging delay the hydraulic uid should have as open channel as
possible:
• The external freewheeling valve should be positioned as close to the motor as
possible.
• All components and lines, which connect the working lines to the case drain line,
should be sized for highest feasible ow rate.
Attention:
Without freewheeling valve, the delay is considerably longer as the uid
must seep through the motor. Disengaging the motor during motion
without a freewheeling valve may cause premature wear or failure of the
motor.
Speed sensor
The speed sensor of the B200 series motors has directional detection and dierent
pulse rates for each frame. Refer to table below for the pulse rates. You can nd the
technical data of the sensor below also. Speed sensor option contains the pulse ring
and the speed sensor. Speed sensor readiness option has the pulse ring without the
sensor. You can install the speed sensor afterwards.
In motors without drum brake the speed sensor protrudes out from the shaft ange,
and it is needed to take account in the counter surface design. Dimensions can be
found from the motor’s datasheet.
3.10
Motor Description
26 Product Manual
Speed sensor
Reading range 0,2 - 2 mm
Supply voltage 8 - 32 VDC
Electrical protection Reverse polarity, short circuit
Current consumption Max. 15 mA
Current load Max. ±50 mA
Output type 2 push-pull frequency signal, push-pull digital
direction output
Signal level Low: < 2 V, High: > Supply-2V
Frequency range 0 to 20 kHz
Material Brass
Temperature range -40 - 125 °C
Protection range IP6K9K / IP67 (sensor side), IP67 (plug con-
nection in mated condition)
Fixing screw / torque M6 / 8 Nm ±2 Nm
Cable and connector
Cable length 1,5 m
Cable type PUR / EVA, 4 x 0,35 mm² unshielded
Connector type 4 pin DEUTSCH DT04-4P
Motor Description
Product Manual 27
Connections
Pin number Function
1
4
3 2
1 Power supply
2 Ground
3 Frequency signal
4 Direction signal
Motor Pulses
B240 70 ppr
B250 80 ppr
B260 96 ppr
B270 112 ppr
Seal protector
The seal protector provides protection for the motor’s seal against outside impurities.
• In dirty environment lubricant is needed to add regularly.
• Lubricate the seal protector as part of the vehicle lubrication routine.
• Observe lubrication adequacy during use and increase or decrease lubrication as
needed. In clean and dry environment there is no need to add lubrication.
• Add lubricant from both nipples during operation. Add lubricant when the motor is
warm.
The lubricant pocket is lled with NLGI-1 lubricant (e.g. Microlube GL 261). Use only
compatible lubricants. The lubricant is mineral oil-based grease which is precipitated
with lithium-soap.
2 1 3
4
• Lubricant pocket (1)
• Grease nipple (2 or 3): position may vary depending on motor model (2 or 3)
• Check valve (4): depending on motor model the seal protector may have check
valve. Possible drainage of lubricant.
• Possible drainage of lubricant (red arrow)
Fittings for one-time lubrication
AAAA-BBBB-CCCCC / NZ - R M S P D T
The lubricating nipples and relief valve are replaced with plugs to prevent adding
lubricant.
3.11
3.11.1
Motor Description
28 Product Manual
Fittings for regular lubrication
AAAA-BBBB-CCCCC / GZ - R M S P D T
The seal protector has nipples to increase the lubricant and a relief valve to
prevent overpressure. More specic locations of these are indicated on the product
datasheet.
Note:
The lubrication eciency can be improved by replacing the relief valve
with a plug (size G1/8"), when the lubricant is starting to drain between
the seal protector and the shaft.
USING THE SEAL PROTECTOR
The seal protector provides the best protection for the motor when lubricant is added
on a regular basis.
• Add lubricant from both nipples during operation. It is recommended to add
lubricant when the motor is warm.
• Lubricate the seal protector as part of the vehicle lubrication routine.
• Observe lubrication adequacy during use and increase or decrease lubrication as
needed.
The lubricant pocket is lled with Microlube GL 261 lubricant or equivalent. Use only
compatible lubricants. The lubricant is mineral oil-based grease which is precipitated
with lithium-soap.
Note:
Some of the lubricant ows past the dirt seal during use. Make sure that
the lubricant does not risk e.g. a disc or a drum brake. If necessary,
the lubricant pocket of the motor can be left empty. (see 1.4 Product
identication).
Figure 22. Possible drainage of lubricant.
3.11.2
Motor Description
Product Manual 29
Drum brake
The three numbers before the last in the drum brake code show the distance of
the lever from the brake in millimeters. For example, on a drum brake with code
MRJ40-0-086-2 the distance between the lever and the brake is 86 mm. The last
number shows the type of the lever: 2 is a manual slack adjuster, 3 is an automatic
slack adjuster.
86 mm
Figure 23. MRJ40-0-086-2 distance between the lever and the brake.
2015/68 ECE R13
Note:
Data given only for information, specic brake calculation has to be done
for each application.
Axle load (kg) Wheels
Test report
#
2015-68|ECE
R13
≤ 30
km/h
> 30
km/h
BF (brake
factor)
Reference
radius
(mm)
Possible
radius
(mm)
Brake
model
ID2 ID3 ID3 ID4
MRJ40 320x75 E 5660 5660 6,46 440 R ≥ 352 361 012 16
MRJ50 400x80 D 8150 8150 11 525 R ≥ 420 361 003 16
MRJ61
420x180
C
13000 13000
12,4(type I)/
11(type III)
546 R ≥ 437 361 045 18
3.12
3.12.1
Motor Description
30 Product Manual
Accessories
Disc brake
It is possible to use disc brakes in the B200 motors without drum brake.
There are disc brake series available for the B240, B250 and B260 motors. For disc
brake series for the B270 motors, contact a representative.
The brake caliper is also available separately for all B200 motor models.
Disc brake series
L1
ØD1
ØD2
L2
Figure 24. Main dimensions of the disc brake series.
MOTOR
B240 B250 B260
Item number K080500000 K000500000 K070500000
Brake
L1
[mm] 148 148 148
L2
[mm] 25,5 28 24
D1 [mm] 460 482 545
D2 [mm] 390 412 468
Max. braking pressure [bar] 150 150 150
Fluid type Mineral oil Mineral oil Mineral oil
Caliper position at 3 or 9 at 3 and 9 at 3 and 9
Braking torque with 1 caliper
[Nm]
1)
4950
Braking torque with 2 calipers
[Nm]
1)
10400 12200
1)
The braking torque is for information only. Braking performance should be ensured
by testing and / or certication.
3.13
3.13.1
Motor Description
Product Manual 31
Brake caliper
L2
L1
Figure 25. Main dimensions of the brake caliper.
MOTOR
B200 series
Item number 1480500000
Brake caliper
L1 [mm] 214
L2 [mm] 148
Max. braking pressure [bar] 150
Fluid type Mineral oil
Caliper position at 3 and/or 9
Braking torque with one caliper [Nm] 3800 - 7600
Torque
[Nm]
3000
3500
4000
4500
5000
5500
6000
6500
7000
7500
8000
300 350 400 450 500 550 600
Figure 26. Disc brake torque.
Brake disc diameter
[mm]
Motor Description
32 Product Manual
Stud bolts
Stud bolts are available from Black Bruin.
Stud bolts
Ø B
D
Ø A
E
C
Item number 1409112400 1409112310 1409112110
ØA M18x1,5 M20x1,5 M22x1,5
ØB M18x1,5 M20x1,5 M22x1,5
C 50 mm 55 mm 42,5 mm
D 25 mm 25 mm 27,5 mm
E 80 mm 85 mm 80 mm
Strength class
1)
10,9
1)
Strength class as in ISO898-1. If using lower strength class, check interface load
capacity and tightening torque.
3.13.2
Motor Description
Product Manual 33
System Design
Motor hydraulic circuit
Simple connection
Figure 27. A simple motor hydraulic circuit in an open loop hydraulic system.
In an open loop hydraulic system the hydraulic circuit of the motor is usually
implemented roughly as in the gure above.
• Select the operating direction with the directional control valve (1) by applying the
working pressure (P) to the other working line (A or B).
• The minimum pressure (see 4.5.3 Working line pressure) required in the return line
(T) is created with the cracking pressure of the check valve (2).
• The case drain line port (C) is connected to the system reservoir (T0) as directly as
possible.
Attention:
The case drain line of the motor must always be connected to a reservoir,
even during freewheeling. The case pressure of the motor may rise
signicantly, if the motor is completely plugged during use.
Note:
Using the motor on a closed loop hydraulic system is dierent from
the open loop system. The closed loop system is more complex, but
enables more functions, such as hydrostatic braking, series connection
and counter pressure operation.
Motors in parallel or series circuit
The traction of a vehicle may be increased by connecting multiple motors in parallel
or in series.
A single powered wheel may transmit only a certain amount of power to traction.
By dividing the power to multiple wheels, the vehicle gets more traction. This is
advantageous especially in slippery operating conditions.
4
4.1
4.1.1
4.1.2
System Design
34 Product Manual
PARALLEL CIRCUIT
Figure 28. Two motors in parallel circuit.
Two motors in parallel circuit generate double torque and run half slower than one
motor with the same ow rate and pressure.
Note:
The ow distribution of the motors must be ensured, if the operating
conditions are very slippery or if some of the powered wheels carry much
smaller load. The system prefers to rotate only the motor, which has the
least resistance.
The ow distribution may be done by sizing the working lines to a certain
ow rate or by throttling them slightly.
Ordinary ow divider valve can not be used in most cases, because
its resistance of ow increases too much as the speed of the vehicle
increases.
The ow distribution is usually required only when starting to move the
vehicle. A reliable solution is a ow divider valve, which can be bypassed
or switched on when necessary.
Figure 29. A pilot controlled ow divider valve.
SERIES CIRCUIT
Figure 30. Two motors in series circuit.
Two motors in series circuit generate same torque and rotate as fast as one motor
with the same ow rate and pressure.
Attention:
The minimum pressure and a sucient feed ow must be ensured for all
motors.
The use of series circuit is challenging and therefore is not recommended.
System Design
Product Manual 35
Counter pressure operation
Counter pressure operation is needed mainly in series connection (see 4.1.2 Motors
in parallel or series circuit). Counter pressure operation means using the motor with
high back pressure in the return line.
The counter pressure operation aects the torque output of the motor due to
decreased pressure dierence over the working lines.
Attention:
Make sure the combined pressure in the working lines does not exceed
the permissible values of the working pressure during counter pressure
operation.
Counter pressure operation is not recommended, because high back
pressure stresses the motor more than usual operation.
Hydrostatic braking
Hydrostatic braking means using the output torque of the motor to decelerate the
speed. The output torque is generated by closing the return line of the motor, in
which case a working pressure will form in the return line. The minimum pressure and
feed ow must be maintained in the feed line of the motor during hydrostatic braking.
Note:
The hydrostatic braking requires an active hydraulic uid supply.
Danger:
Do not use the hydrostatic braking without relief valves in the working
lines. When an external load is rotating the motor, the hydraulic pressure
may increase indenitely. This leads to danger if a hydraulic hose or
component brakes under high pressure.
Short circuit operation
Short circuit operation means connecting the return
ow of the motor directly to the
feed line of the motor.
Short circuit operation is needed, if the motor must be rotated faster than the
hydraulic system can supply and freewheeling the motor is not possible (see 3.9.2
Mechanical freewheeling).
Make sure the minimum pressure is maintained in both working lines of the motor
during short circuit operation.
Note:
The short circuit operation requires an active hydraulic uid supply.
Attention:
Make sure the motor does not overheat during short circuit operation.
4.1.3
4.1.4
4.1.5
System Design
36 Product Manual
Hydraulic connections
Figure 31. The interface of the motor
hydraulics.
Figure 32. The hydraulic connections.
All hydraulic connections of the motor are on the shaft mating surface.
• WORKING LINE PORTS (A and B)
The working lines, aka the feed and return lines of the motor are the high pressure
lines meant for running the motor.
• CASE DRAIN LINE PORT (C)
The case drain line is the return line from the housing cavity.
• PILOT LINE PORT (F or Y)
The pilot line is meant for controlling the 2-speed or freewheeling valve of the
motor (see 3.7 2-speed valve : 2NRxx / 2NLxx and 3.8 Freewheeling valve in:
FW11x / FW21x ).
External freewheeling valve
The external freewheeling valve is used for disengaging the motor during motion (see
3.9.2 Mechanical freewheeling).
The freewheeling valve should be normally open, so that the motor will disengage
when the control system is o.
When the motor is disengaged the case drain port (C) should be connected as directly
as possible to the working line ports A and B.
There are multiple possibilities for the external freewheeling valve. Some examples of
these possibilities are described in this chapter.
4.2
4.3
System Design
Product Manual 37
B200 series with mechanical freewheeling
2/2 VALVE
• When the motor is disengaged using the
2/2 valve (6a), the directional control valve
(1) should have “Y” spool mid position.
Use of the 2/2 valve may be optimized by
switching the freewheeling valve (6a) just
before (max. 0,5 s) the directional control
valve (1). This reduces the pressure in the
return line and minimizes the disengaging
delay.
Figure 33. Freewheeling circuit with a 2/2
valve.
4/2 VALVE
• Using the 4/2 valve (6b) may be neces-
sary, if the size of the directional control
valve (1) limits the disengaging delay.
Use of the 4/2 valve may be optimized
by switching the directional control valve
(1) just before (max. 0,5 s) the freewheel-
ing valve (6b). This prevents case pressure
peak caused by working pressure.
Figure 34. Freewheeling circuit with a 4/2
valve.
6/2 VALVE
• With the 6/2 valve (6c), the motor may be
disengaged using only the freewheeling
valve.
The 6/2 valve is reliable as the external
freewheeling valve, but it must be sized
for full working line ow rate.
Figure 35. Freewheeling circuit with a 6/2
valve.
System Design
38 Product Manual
Hydraulic uid
Hydraulic uid type
Black Bruin hydraulic motors are designed to work with hydraulic uids based on
mineral oil. Consider the following requirements when choosing hydraulic uid:
• Hydraulic oils in accordance with ISO 6743-4 are recommended to be used.
• Motor oils in accordance with API-grades SF, SG, SH and SL may also be used.
• Fire resistant hydraulic uids HFB and HFC or similar may be used under certain
circumstances.
Hydraulic uid properties
Requirements concerning the hydraulic uid properties:
• The recommended uid viscosity range for constant use is 25 - 50 cSt.
• The minimum permissible intermittent viscosity is 15 cSt.
• The maximum permissible viscosity during motor startup is 1000 cSt.
• The viscosity index must be at least 100.
• The water content of hydraulic oil should be less than 500 ppm (0,05 %).
• The hydraulic uid must reach score 10 on a wear protection test FZG A/8,3/90 in
accordance with ISO 14635-1 (DIN 51354)
• The eect of the additives improving the viscosity index can decrease during
operation.
Note:
Temperature has a signicant eect on the viscosity and the lubricating
capability of the hydraulic uid. Take into consideration the real operating
temperature when dening the uid viscosity.
The need for service and the overall service life may be improved by
using hydraulic uids with higher viscosity. In addition higher viscosity
may improve the running smoothness.
Hydraulic uid cleanliness
Hydraulic
uid must fulll cleanliness level 18/16/13 in accordance with ISO 4406
(NAS 1638 grade 7).
Note:
The purity of the hydraulic uid has a signicant eect on the need for
service and the overall service life of the motor.
Operating pressures
Case pressure
The case pressure of the motor aects the lifetime of the sealing. It is recommended
to maintain as low case pressure as possible.
When the motor is running, the permissible average case pressure is 2 bar and the
highest permissible intermittent case pressure is 10 bar.
When the motor is not running, the highest permissible constant case pressure is 10
bar.
4.4
4.4.1
4.4.2
4.4.3
4.5
4.5.1
System Design
Product Manual 39
Attention:
Running the motor with higher than allowed case pressure shortens the
service life of the motor.
Note:
The lifetime of the sealing may be improved with an accumulator, which
cuts the pressure peaks that are higher than the pre-charge pressure of
the accumulator.
Recommended pre-charge pressure is 2 bar and the displacement should
be about 25 % of the motor displacement. The accumulator should be
connected to the case drain line port as close to the motor as possible.
Pilot pressure
AAAA - BBBB - 2NRxx / D
AAAA - BBBB - 2NLxx / D
AAAA - BBBB - FW11x / D
AAAA - BBBB - FW21x / D
The pilot pressure is used to engage the 2-speed or freewheeling valve of the motor.
The recommended pilot pressure is 15 to 30 bar and the maximum allowed pilot
pressure is 350 bar.
Attention:
Over 30 bar pilot pressure causes case pressure peaks. This eect should
be minimized with an orice in the pilot line. Recommended orice size is 1
mm.
Working line pressure
WORKING PRESSURE
The working pressure is the high pressure that generates the output torque of the
motor. The following values for the working pressure are in the technical data (see 3.3
Technical data):
• PEAK PRESSURE
The value of the peak pressure is the maximum allowed value of the working
pressure. Make sure the working pressure does not exceed this value under any
circumstances.
• INTERMITTENT PRESSURE
The value of the intermittent pressure is a permissible value of the working
pressure for a reference period of one minute (1 min). The working pressure may
exceed this value for 10 % of the time during the reference period (for 6 seconds).
MINIMUM PRESSURE
The minimum pressure is a low pressure required in the working lines, which ensures
the motor stays engaged when running. The motor is engaged when the pistons of
the motor stay constantly connected to the cam ring.
The minimum pressure is maintained with back pressure or charge pressure. Type of
the hydraulic system aects the implementation.
4.5.2
4.5.3
System Design
40 Product Manual
• BACK PRESSURE
In open loop hydraulic system the minimum pressure may be done with back
pressure. The back pressure is usually generated by a suitable check valve with
cracking pressure.
• CHARGE PRESSURE
In closed loop hydraulic system the charge pressure is usually used as the
minimum pressure.
In open loop hydraulic system the charge pressure may be done by a suitable
pressure reducing valve.
The required minimum pressure depends mainly on the ow rate in the working lines.
Recommended values for the minimum pressure are on the following gures:
WORKING LINE PRESSURE
[bar]
Figure 36. The minimum pressure at full
displacement (uid viscosity 35 cSt).
[bar]
Flow rate [l/min]
WORKING LINE PRESSURE
[bar]
Figure 37. The minimum pressure at half
displacement (uid viscosity 35 cSt).
[bar]
Flow rate [l/min]
Attention:
Too low pressure in the working lines causes the pistons to disconnect
from the cam ring when the motor is running. The eect of this is a
clattering noise when the pistons hit the cam ring again.
System Design
Product Manual 41
Constant use with too low working line pressure may cause premature
wear or failure of the motor.
System Design
42 Product Manual
Motor Sizing
Load carrying capacity
Wheel oset
The load carrying capacity of the motor is dened by the oset value (a) of the wheel
rim and the application specic safety factor.
The oset value is the distance from the wheel center line (CL) to the motor shaft
interface. The load charts of the motors are given as a function of oset value. The
given load curves refer to the average wheel load on a single motor.
CL
a (mm)
Figure 38. Measurement of the wheel oset (a).
Attention:
The motor load carrying capacity is applicable when the C or C2 port is
orientated to the load direction.
Figure 39. Motor orientation to the load direction.
5
5.1
5.1.1
Motor Sizing
Product Manual 43
Allowed wheel load
The allowed wheel load is based on the fatigue strength of the shaft (curved part)
and the load carrying capacity of the screw joints (at part). The maximum allowed
wheel load depends on the load point. With applications combining high radial and
axial loads, please consult the motor manufacturer or its representative to determine
maximum permissible loading.
a (mm)
r (m)
F
a
(kN)
F
r
(kN)
B240:
B250:
B260:
B270:
F
max
≥ α x F
r
+ 5,3 x r x F
a
F
max
≥ α x F
r
+ 4,6 x r x F
a
F
max
≥ α x F
r
+ 4,0 x r x F
a
F
max
≥ α x F
r
+ 3,4 x r x F
a
Dynamic factor (α):
• constant loading at low speed, α = 1
• variable loading, α = 1 - 1,5
• shock loads or high speed (for > 70 km/h
or 45 mph), α = 1,4 - 2
MOTOR LOAD CURVE: B240
F
max
[kN]
Figure 40. Motor load carrying capacity Fmax.
Wheel o-
set, a [mm]
MOTOR LOAD CURVE: B250, B260 AND B270
F
max
[kN]
Figure 41. Motor load carrying capacity Fmax.
Wheel o-
set, a [mm]
5.1.2
Motor Sizing
44 Product Manual
Service life
The service life of the motor is based on the rated life of its bearings. The bearings
load curve gives the wheel load value, which the motors endure for 10 million
rotations with 90 % reliability.
The service life may be estimated with the following equation:
L
10h
= nominal service life [h]
RPM = rotating speed [rpm]
G = average wheel load [kN]
F
10m
= bearing load carrying capacity [kN]
BEARINGS LOAD CURVE: B240 and B250
Load
[kN]
Figure 42. Bearing load carrying capacity F10m.
Wheel o-
set, a[mm]
BEARINGS LOAD CURVE: B260 and B270
Load
[kN]
Figure 43. Bearing load carrying capacity F10m.
Wheel o-
set, a[mm]
5.1.3
Motor Sizing
Product Manual 45
Axial load capacity
C
E
F
F
Figure 44. Axial load capacity of the motor.
Max. axial load, without radial load
B240 B250 B260 B270
Compression (F
C
) 81 kN 125 kN 123 kN 185 kN
Expansion (F
E
) 39 kN 61 kN 91 kN 115 kN
Performance
Rotating speed and ow rate
Rotating speed of the motor and required ow rate may be calculated with the
following equations:
ROTATING SPEED
or
RPM = rotating speed [rpm]
KMH = vehicle speed [km/h]
MPS = vehicle speed [m/s]
R = wheel radius [mm]
V = displacement [ccm]
Q = ow rate in working lines [l/min]
or
FLOW RATE
Note:
Due to motor dynamics, a constant smooth operating speed of under 2
rpm may be dicult to achieve.
5.1.4
5.2
5.2.1
Motor Sizing
46 Product Manual
WORKING SPEED - WHEEL RADIUS
speed [rpm]
Figure 45. Vehicle speed and motor rotat-
ing speed with dierent wheel radius.
speed [km/h]
speed [m/s]
FREEWHEELING SPEED - WHEEL RADIUS
speed [rpm]
Figure 46. Vehicle freewheeling speed and
motor rotating speed with dierent wheel
radius.
speed [km/h]
speed [m/s]
Torque
The output torque of the motor is generated by the pressure dierence of the
working lines (pressure dierence between ports A and B)
The output torque of the motor may be estimated with the following equations:
MAXIMUM TORQUE
T = torque [Nm]
5.2.2
Motor Sizing
Product Manual 47
V = displacement [ccm]
Δp = pressure dierence [bar]
STARTUP TORQUE
Power
The operating power of the motor should be determined for all operating conditions.
The operating power may be calculated with the following equation:
P = power [kW]
Q = ow rate in working lines [l/min]
RPM = rotating speed [rpm]
V = displacement [ccm]
p
w
= working pressure [bar]
or
Note:
Rough estimate of the operating power may be checked by dividing the
available hydraulic power between the motors.
Performance charts
B240 motors performance curves
Torque
[Nm]
Figure 47. Performance curves B240,
500ccm (uid viscosity 35cSt).
Max. power
35 kW
Max. speed
300 rpm
Speed
[rpm]
5.2.3
5.3
5.3.1
Motor Sizing
48 Product Manual
Torque
[Nm]
Figure 48. Performance curves B240,
630ccm (uid viscosity 35cSt).
Max. power
35 kW
Max. speed
240 rpm
Speed
[rpm]
Torque
[Nm]
Figure 49. Performance curves B240,
800ccm (uid viscosity 35cSt).
Max. power
35 kW
Max. speed
185 rpm
Speed
[rpm]
Motor Sizing
Product Manual 49
B250 motors performance curves
Torque
[Nm]
Figure 50. Performance curves B250,
1000ccm (uid viscosity 35cSt).
Max. power
50 kW
Max. speed
200 rpm
Speed
[rpm]
Torque
[Nm]
Figure 51. Performance curves B250,
1250ccm (uid viscosity 35cSt).
Max. power
50 kW
Max. speed
160 rpm
Speed
[rpm]
5.3.2
Motor Sizing
50 Product Manual
Torque
[Nm]
Figure 52. Performance curves B250,
1600ccm (uid viscosity 35cSt).
Max. power
50 kW
Max. speed
125 rpm
Speed
[rpm]
B260 motors performance curves
Torque
[kNm]
Figure 53. Performance curves B260,
2000ccm (uid viscosity 35cSt).
Max. power
90 kW
Max. speed
175 rpm
Speed
[rpm]
5.3.3
Motor Sizing
Product Manual 51
Torque
[kNm]
Figure 54. Performance curves B260,
2500ccm (uid viscosity 35cSt).
Max. power
90 kW
Max. speed
140 rpm
Speed
[rpm]
Torque
[kNm]
Figure 55. Performance curves B260,
3150ccm (uid viscosity 35cSt).
Max. power
90 kW
Max. speed
110 rpm
Speed
[rpm]
Motor Sizing
52 Product Manual
B270 motors performance curves
Torque
[kNm]
Figure 56. Performance curves B270,
4000ccm (uid viscosity 35cSt).
Max. power
130 kW
Max. speed
125 rpm
Speed
[rpm]
Torque
[kNm]
Figure 57. Performance curves B270,
5000ccm (uid viscosity 35cSt).
Max. power
130 kW
Max. speed
100 rpm
Speed
[rpm]
5.3.4
Motor Sizing
Product Manual 53
Torque
[kNm]
Figure 58. Performance curves B270,
6300ccm (uid viscosity 35cSt).
Max. power
130 kW
Max. speed
80 rpm
Speed
[rpm]
B200 motors case leakage
[l/min]
Figure 59. Case leakage curves of B200
series motors (uid viscosity 35 cSt).
Pressure
[bar]
5.4
Motor Sizing
54 Product Manual
Installation Instructions
Mounting the motor
The installation dimensions and tightening torques are given in the product
datasheet.
Check the following things before installing the motor:
• The counter surfaces must be clean and even.
• Make sure that the strength class (grade) of the fastening screws is sucient.
• Make sure that the fastening screws are of suitable size and length.
• The fastening screws should be cleaned and oiled lightly before installing them.
• Use threadlocker only if necessary, removing the old threadlocker may be dicult.
• Remove any old threadlocker before mounting the motor.
Note:
When replacing fastening screws with new ones, renew all of the screws.
Attention:
When using stud bolts, do not tighten the bolt. Tightening of the stud bolt
is done with the nut.
Figure 60. Stud bolt variants.
Flushing the hydraulic system
Prior to connecting the motor as part of the hydraulic system, the hydraulic circuit
of the motor must always be ushed by circulating hydraulic uid through a lter
installed in place of the motor.
The ushing is carried out by circulating hydraulic uid through the entire system
with a minimum pressure for at least an hour.
• After ushing, renew all lters.
Note:
Flushing the hydraulic system should also be performed after every
system modication or repair.
Air bleeding procedure
Air bleeding procedure is carried out to ll the housing of the motor completely with
hydraulic uid. Air is removed from the housing with air bleeding screws as follows:
• Locate the air bleeding screws of the housing and turn the motor to a position in
which the screw is at its topmost position.
• Make sure the drain line of the motor is connected.
6
6.1
6.2
6.3
Installation Instructions
Product Manual 55
• Feed hydraulic uid into the motor with low pressure throughout the procedure.
• Unscrew the air bleeding screw by half a turn and let air escape from the housing.
• Close the screw when only hydraulic uid is pouring through it.
• Tighten the screw to a torque of 39 ± 3 Nm.
The location of the air bleed screws is given in the product datasheet.
Note:
If feed pressure is not available, ll the housing manually by pouring
hydraulic uid in the motor through the topmost opening of the housing.
Commissioning procedure
Ensure that the following things are in order before starting a new or replaced motor:
• The hydraulic circuit of the motor is ushed.
• Motor is installed appropriately.
• Air bleeding procedure is carried out.
• The reservoir of the hydraulic system is full.
During the initial stages of use, also take the following things into consideration:
• Do not run the motor immediately with full power. Increase the load and speed of
rotation gradually.
• Observe the motor and the hydraulic system for external leaks or abnormal noises
during the commissioning procedure.
• Start the motor break-in.
Note:
During all installation and service procedures, plug any open ports and
hoses.
When lling the reservoir, add hydraulic uid through a lter.
Attention:
Do not start the motor, if the air bleeding procedure has not been carried
out.
Stressing an unused motor with full power may cause premature wear or
failure of the motor.
6.4
Installation Instructions
56 Product Manual
Operating Instructions
Break-in period
The motor achieves its nal properties during the rst hours of use. Therefore all new
and reconditioned motors should go through an initial break-in period.
Things to be considered during break-in period:
• The break-in period should last for at least rst eight hours (8 h) of use.
• The power output should remain under 50 % of the maximum power capacity of
the motor.
• The power output is limited by limiting the working pressure, the speed of rotation
or both.
• The working pressure should be limited so, that pressure peaks which last over
two seconds (2 s) remain under 75 % of the permissible values.
Note:
During the break-in period, the moving parts of the motor wear against
each other so, that the wear of the parts sets to a stable state for the
entire service life of the motor.
Use
Things to be considered during use of motors:
• Check the screw connections tightening torque and hydraulic connections
regularly.
• Do not use pressure cleaning directly between the shaft ange and housing of the
motor (the shaft seal area).
• Avoid situations in which the motors are completely submerged in water or mud.
Operating temperature
The operating temperature means the internal temperature of the motor. Take into
considerations the following requirements for the operating temperature:
• For improved service life, avoid over 70 °C (158 °F) operating temperature.
• The highest permissible intermittent operating temperature is 85 °C (185 °F).
• The lowest permissible operating temperature is -35 °C (-31 °F).
• The temperature dierence between the motor and the hydraulic uid should be
under 60 °C (140 °F).
The operating temperature may be measured from the hydraulic uid returning from
the motor. Take into account the temperature of hydraulic uid returning from the
drain line and from the return line (A or B).
Demounting the motor
Take into consideration the following things when demounting the motor for service
or replacement:
• Release the pressure in the hydraulic lines and let the motor cool down.
• Disconnect all the hydraulic lines from the motor and plug all openings and hoses.
• Demount the motor and lift it away from its position.
7
7.1
7.2
7.3
7.4
Operating Instructions
Product Manual 57
• Clean the outside of the motor thoroughly, but do not use any solvents.
• Protect the cleaned motor from corrosion.
• If possible, drain all the hydraulic uid from the motor.
Note:
Dispose of hydraulic uid should be done appropriately.
Operating Instructions
58 Product Manual
Special Instructions
Storing the motor
During short term storage of the motor, the following should be taken into
consideration:
• Cover any pressure openings and open threaded holes with suitable caps.
• Protect the unpainted surfaces from dirt and moisture.
• Store the motor in a dry place with relatively stable temperature.
• The motor should not be stored in a same place as substances with aggressive
corrosive nature (solvents, acids, alkalis and salts).
• The motor should not be exposed to strong magnetic elds.
• The motor should not be exposed to strong vibration.
Note:
For long-term storage (over 9 months) the following additional actions are
recommended:
• Damages to surface paint must be repaired.
• Protect the unpainted surfaces with suitable anti-corrosion treatment.
• Fill the motor completely with hydraulic uid.
If these instructions are followed, the motor may be stored for
approximately two years. However, as storage conditions do have a
signicant eect, these times should only be considered as guide values.
8
8.1
Special Instructions
Product Manual 59
60 Product Manual
Black Bruin Inc.
+358 20 755 0755
P.O. Box 633, FI-40101 JYVÄSKYLÄ, FINLAND
www.blackbruin.com
info@blackbruin.com
All the information contained in this publication is based on the latest information available at the time of publication.
Black Bruin Inc. reserves the right to make changes without prior notice.
EN 20231106