Product Manual
BB and BBC 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 Motor model code BB series.........................................................................................................................8
3.3 Motor model code BBC series...................................................................................................................... 9
3.4 Technical data BB series..............................................................................................................................10
3.5 Technical data BBC series........................................................................................................................... 12
3.6 Motor interfaces............................................................................................................................................. 14
3.6.1 Main dimensions..........................................................................................................................14
3.6.2 Shaft interfaces........................................................................................................................... 16
3.6.3 Hub interfaces..............................................................................................................................21
3.7 Rotating direction..........................................................................................................................................25
3.8 Freewheeling..................................................................................................................................................26
3.8.1 Hydrostatic freewheeling......................................................................................................... 26
3.8.2 Mechanical freewheeling.......................................................................................................... 27
3.9 1-speed motors..............................................................................................................................................28
3.10 Multi-speed motors...................................................................................................................................... 29
3.11 Seal protector and grease nipples.............................................................................................................31
3.12 Brakes................................................................................................................................................................31
3.12.1 Static wet multi-disc brake for BBC and BB series motors..............................................31
3.12.2 Double brake for BBC series motors......................................................................................32
4 System Design................................................................................. 33
4.1 Motor hydraulic circuit................................................................................................................................. 33
4.1.1 Simple connection......................................................................................................................33
4.1.2 Counter pressure operation..................................................................................................... 33
4.1.3 Hydrostatic braking....................................................................................................................34
4.1.4 Short circuit operation...............................................................................................................34
4.2 Hydraulic connections................................................................................................................................. 35
4.3 External freewheeling valve........................................................................................................................37
4.4 Hydraulic uid................................................................................................................................................ 39
4.4.1 Motors in parallel or series circuit...........................................................................................39
4.4.2 Hydraulic uid type.....................................................................................................................41
4.4.3 Hydraulic uid properties.......................................................................................................... 41
4.4.4 Hydraulic uid cleanliness.........................................................................................................41
4.5 Operating pressures...................................................................................................................................... 41
4.5.1 Case pressure...............................................................................................................................41
4.5.2 Pilot pressure............................................................................................................................... 42
4.5.3 Working line pressure.................................................................................................................42
Contents
2 Product Manual
5 Motor Sizing..................................................................................... 46
5.1 Load carrying capacity................................................................................................................................ 46
5.1.1 Wheel oset..................................................................................................................................46
5.1.2 Allowed wheel load.....................................................................................................................47
5.1.3 Service life....................................................................................................................................48
5.2 Performance...................................................................................................................................................50
5.2.1 Rotating speed and ow rate.................................................................................................. 50
5.2.2 Torque.............................................................................................................................................51
5.2.3 Power............................................................................................................................................. 52
5.3 Performance charts......................................................................................................................................52
5.3.1 BB motors performance curves..............................................................................................52
5.3.2 BBC motors performance curves...........................................................................................58
5.3.3 BB motors case leakage............................................................................................................62
5.3.4 BBC motors case leakage.........................................................................................................63
6 Installation Instructions................................................................ 64
6.1 Conditions of installation and application.............................................................................................. 64
6.2 Mounting the motor......................................................................................................................................64
6.3 Flushing the hydraulic system...................................................................................................................64
6.4 Hydraulic connections................................................................................................................................. 65
6.5 Air bleeding procedure.................................................................................................................................65
6.6 Commissioning procedure..........................................................................................................................65
6.7 Tightening torques........................................................................................................................................66
7 Operating Instructions................................................................... 67
7.1 Break-in period...............................................................................................................................................67
7.2 Use.....................................................................................................................................................................67
7.3 Operating temperature.................................................................................................................................67
7.4 Demounting the motor.................................................................................................................................67
8 Special Instructions........................................................................69
8.1 Storing the motor..........................................................................................................................................69
Contents
Product Manual 3
General Instructions
About the manual
This manual contains the technical instructions for the Black Bruin BB and BBC 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 BB and BBC 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
06.06.2023 - 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
BB and BBC 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
Motor model code BB series
BB SERIES MODEL CODE 40DVVVYW40
Hydraulic motors with parking brake
40 40DVVVYW40
BB series standard code
D: Motor frame size 40DVVVYW40 BB 4 BB 5 BB 6 BB 7
BB 4: 630-800 ccm 4 ●
BB 5: 1000-1600 ccm 5 ●
BB 6: 2000-3150 ccm 6 ●
BB 7: 4000-6300 ccm 7 ●
VVV: Motor displacement 40DVVVYW40 BB 4 BB 5 BB 6 BB 7
BB 4 displacements
063 : 630 ccm/rev ●
080 : 800 ccm/rev ●
100 : 1000 ccm/rev ●
BB 5 displacements 125 : 1250 cmm/rev ●
160 : 1600 ccm/rev ●
200 : 2000 ccm/rev ●
BB 6 displacements 250 : 2500 ccm/rev ●
315 : 3150 ccm/rev ●
400 : 4000 ccm/rev ●
BB 7 displacements 500 : 5000 ccm/rev ●
630 : 6300 ccm/rev ●
Y: Freewheeling 40DVVVYW40 BB 4 BB 5 BB 6 BB 7
Hydraulic freewheeling 1 ● ● ● ●
Mechanical freewheeling 2 ● ● ● ●
W: Multi-speed option 40DVVVYW40 BB 4 BB 5 BB 6 BB 7
Fixed displacement 1 ● ● ● ●
2-speed 2 : CW rotation ● ● ● ●
2-speed 3 : CCW rotation ● ● ● ●
Code example 4051602140
40DVVVYW40
40 = The motor model series is "BB"
D = The frame of the motor is "BB 5"
VVV = The displacement of the motor is 1600 ccm
Y = The motor with mechanical freewheeling
W = The motor with xed displacement
3.2
Motor Description
8 Product Manual
Code example 4051602140
4 = The motor with a wet multi-disc parking brake
0 = The motor is a standard motor
Motor model code BBC series
BBC SERIES MODEL CODE CDVWE1Y0AA
Hydraulic motors
C C DVWE1Y0AA
BBC series standard code
D: Motor frame size CDVWE1Y0AA BBC 02 BBC 03 BBC 05
BBC 02: 705-1018 ccm 2 ●
BBC 03: 909-1313 ccm 3 ●
BBC 05: 1572-2271 ccm 5 ●
V: Motor displacement CDVWE1Y0AA BBC 02 BBC 03 BBC 05
1 : 705 ccm/rev ●
BBC 02 displacements 3 : 862 ccm/rev ●
5 : 1018 ccm/rev ●
1 : 909 ccm/rev ●
BBC 03 displacements 3 : 1111 ccm/rev ●
5 : 1313 ccm/rev ●
1 : 1572 ccm/rev ●
BBC 05 displacements 3 : 1922 ccm/rev ●
5 : 2271 ccm/rev ●
W: Multi-speed option CDVWE1Y0AA BBC 02 BBC 03 BBC 05
1-speed 1 : Fixed displacement ● ● ●
2-speed 2 : 100 / 50% displacement ● ● ●
4-speed
7 : 100 / 75 / 50 / 25 % dis-
placement
●
E: Brake option CDVWE1Y0AA BBC 02 BBC 03 BBC 05
Without brake 0 ● ● ●
Static wet multi-disc brake 1 ● ● ●
Dynamic brake + static wet mul-
ti-disc parking brake
C ● ●
Y: Freewheeling CDVWE1Y0AA BBC 02 BBC 03 BBC 05
Hydraulic freewheeling 0 ● ● ●
Mechanical freewheeling 1 ● ● ●
3.3
Motor Description
Product Manual 9
Code example C2321110AA
CDVWE1Y0AA
C = The motor model series is "BBC"
D = The frame of the motor is "BBC 02"
V = The displacement of the motor is 862 ccm
W = The motor with a 2-speed valve (862 ccm - 1/1 displ., 431 ccm - 1/2 displ.)
E = The motor with a wet multi-disc parking brake
1 = The motor with a case ushing line
Y = The motor with mechanical freewheeling
0 = N/A
AA = The motor is a standard motor
Technical data BB series
TECHNICAL DATA BB 4 BB 5
Displacement [ccm] 630 800 1000 1250 1600
Maximum torque [Nm]
peak torque 3300 4190 5240 6540 8380
intermittent 2825 3590 4490 5610 7180
Max. operating power [kW]
at full displacement 35 50
at partial displacement 21 30
Max. rotating speed [rpm]
at full displacement 240 185 200 160 125
at partial displacement 360 275 300 240 185
at freewheeling 600 500
Min. rotating speed [rpm] 2 2
Max. working pressure [bar]
peak pressure 350 350
intermittent
1)
300 300
Max. case pressure [bar]
average 2 2
intermittent
1)
10 10
Pilot pressure for internal valve [bar]
valve released 0-2 0-2
valve engaged 15-30
2)
15-30
2)
Max. ow rate [l/min]
at full displacement 150 200
at partial displacement 113 150
Spring operated wet multi-disc brake
(parking brake)
brake torque (min.) [Nm]
3)
3700 8000
3.4
Motor Description
10 Product Manual
TECHNICAL DATA BB 4 BB 5
releasing pressure [bar] 70 86
brake pressure (max.)
[bar]
300 300
needed oil volume [ccm] 30 40
Weight [kg] 66 114
TECHNICAL DATA BB 6 BB 7
Displacement [ccm] 2000 2500 3150 4000 5000 6300
Maximum torque [Nm]
peak torque 13440 16810 21170 26890 33530 42300
intermittent 11950 14940 18820 23900 29800 37600
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 220 180 145 160 130 105
at freewheeling 400 350
Min. rotating speed [rpm] 2 2
Max. working pressure [bar]
peak pressure 450 450
intermittent
1)
400 400
Max. case pressure [bar]
average 2 2
intermittent
1)
10 10
Pilot pressure for internal valve [bar]
valve released 0-2 0-2
valve engaged 15-30
2)
15-30
2)
Max. ow rate [l/min]
at full displacement 350 500
at partial displacement 225 325
Spring operated wet multi-disc brake
(parking brake)
brake torque (min.) [Nm]
3)
20000 40000
releasing pressure [bar] 52 63
brake pressure (max.)
[bar]
250 250
needed oil volume [ccm] 110 140
Weight [kg] 189 365
1)
Intermittent operation: permissible values for maximum of 10% of every minute.
2)
If pilot pressure over 30 bar is used, the pilot line should be throttled.
Motor Description
Product Manual 11
3)
Brake torque for new brake.
Technical data BBC series
TECHNICAL DATA BBC 02 BBC 03
Displacement [ccm] 705 862 1018 909 1111 1313
Maximum torque [Nm]
peak torque 4645 5680 5965 5990 7320 7690
intermittent 4130 5050 5220 5325 6510 6730
Max. operating power [kW]
at full displacement 42 50
at partial displacement 28 33
Max. rotating speed [rpm]
at full displacement 223 182 154 206 169 143
at partial displacement 318 260 220 290 238 201
at freewheeling 450 425
Min. rotating speed [rpm] 2 2
Max. working pressure [bar]
peak pressure 450 450 400 450 450 400
intermittent
1)
400 400 350 400 400 350
Max. case pressure [bar]
average 2 2
intermittent
1)
10 10
Pilot pressure for internal valve [bar]
valve released 0-2 0-2
valve engaged 15-30
2)
15-30
2)
Max. ow rate [l/min]
at full displacement 157 187
at partial displacement 112 132
Spring operated wet multi-disc brake
(parking brake)
brake torque (min.) [Nm]
3)
6560 8470
releasing pressure [bar] 16 16
brake pressure (max.)
[bar]
30 30
needed oil volume [ccm] 120 150
Dynamic multi-disc brake (service brake)
brake torque (min.) [Nm]
3)
7800 10700
brake pressure (max.)
[bar]
60 60
Weight [kg]
without brake 62 80
3.5
Motor Description
12 Product Manual
TECHNICAL DATA BBC 02 BBC 03
with parking brake 72 96
with double brake 122 148
TECHNICAL DATA BBC 05
Displacement [ccm] 1572 1922 2271
Maximum torque [Nm]
peak torque 10360 12670 13305
intermittent 9210 11260 11640
Max. operating power [kW]
at full displacement 72
at 3/4 displacement 60
at partial displacement 48
at 1/4 displacement 32
Max. rotating speed [rpm]
at full displacement 172 141 119
at 3/4 displacement 205 168 142
at partial displacement 244 200 169
at 1/4 displacement 326 266 226
at freewheeling 400
Min. rotating speed [rpm] 2
Max. working pressure [bar]
peak pressure 450 450 400
intermittent
1)
400 400 350
Max. case pressure [bar]
average 2
intermittent
1)
10
Pilot pressure for internal valve [bar]
valve released 0-2
valve engaged 15-30
2)
Max. ow rate [l/min]
at full displacement 270
at 3/4 displacement 242
at partial displacement 192
at 1/4 displacement 128
Spring operated wet multi-disc brake
(parking brake)
brake torque (min.) [Nm]
3)
20600
releasing pressure [bar] 16
brake pressure (max.)
[bar]
30
needed oil volume [ccm] 260
Motor Description
Product Manual 13
TECHNICAL DATA BBC 05
Weight [kg]
without brake 138
with parking brake 158
1)
Intermittent operation: permissible values for maximum of 10% of every minute.
2)
If pilot pressure over 30 bar is used, the pilot line should be throttled.
3)
Brake torque for new brake.
Motor interfaces
Main dimensions
BB series motors with static multi-disc brake
L2
L1
ØD1
Figure 5. Main dimensions of the motor.
MAIN DIMENSIONS
BB 4 BB 5 BB 6 BB 7
Motor
L1 [mm] 420 469 480 550
L2 [mm] 265 282 320 382
D1 [mm] 278 342 408 512
3.6
3.6.1
Motor Description
14 Product Manual
BBC series motors without brake
L2
L1
ØD1
Figure 6. Main dimensions of the motor.
MAIN DIMENSIONS
BBC 02 BBC 03 BBC 05
Motor
L1 [mm] 254 268 298
L2 [mm] 233 241 259
D1 [mm] 282 315 376
BBC series motors with static multi-disc brake
L2
L1
ØD1
Figure 7. Main dimensions of the motor.
Motor Description
Product Manual 15
MAIN DIMENSIONS BBC 02 BBC 03 BBC 05
Motor
L1 [mm] 322 331 383
L2 [mm] 236 241 263
D1 [mm] 282 315 376
BBC series motors with double brake
L1
ØD1
L2
Figure 8. Main dimensions of the motor.
MAIN DIMENSIONS
BBC 02 BBC 03
Motor
L1 [mm] 353 364
L2 [mm] 267 274
D1 [mm] 360 360
Shaft interfaces
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.
3.6.2
Motor Description
16 Product Manual
BB series motors with static multi-disc brake
C1
R1
ØD2
ØD3
ØD1
Figure 9. Dimensions of the shaft interface.
INTERFACE DIMENSIONS
BB 4 BB 5 BB 6 BB 7
Shaft interface
D1 [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
D2 min.
3)
[mm] 114 150 170 220
D3 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.
Motor Description
Product Manual 17
BBC series motors without brake
C1
R1
ØD1
ØD2
ØD3
Figure 10. Dimensions of the shaft interface.
INTERFACE DIMENSIONS
BBC 02 BBC 03 BBC 05
Shaft interface
D1 [mm] 160 175 200
pattern 8x45° 10x36° 12x30°
size M16x2,0 M16x2,0 M20x1,5
strength class
1)
12,9 12,9 12,9
tightening tor-
que
2)
[Nm]
330 330 650
D2 min.
3)
[mm] 135 150 166
D3 min.
4)
[mm] 200 216 240
R1 max. [mm] 1 1 1
C1 [mm] 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.
Motor Description
18 Product Manual
BBC series motors with static multi-disc brake
C1
R1
ØD2
ØD3
ØD1
Figure 11. Dimensions of the shaft interface.
INTERFACE DIMENSIONS
BBC 02 BBC 03 BBC 05
Shaft interface
D1 [mm] 160 175 200
pattern 8x45° 10x36° 12x30°
size M16x2,0 M16x2,0 M20x1,5
strength class
1)
12,9 12,9 12,9
tightening tor-
que
2)
[Nm]
330 330 650
D2 min.
3)
[mm] 135 150 166
D3 min.
4)
[mm] 200 216 240
R1 max. [mm] 1 1 1
C1 [mm] 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.
Motor Description
Product Manual 19
BBC series motors with double brake
C1
R1
ØD2
ØD3
ØD1
Figure 12. Dimensions of the shaft interface.
INTERFACE DIMENSIONS
BBC 02 BBC 03
Shaft interface
D1 [mm] 160 175
pattern 8x45° 10x36°
size M16x2,0 M16x2,0
strength class
1)
12,9 12,9
tightening tor-
que
2)
[Nm]
330 330
D2 min.
3)
[mm] 135 150
D3 min.
4)
[mm] 200 216
R1 max. [mm] 1 1
C1 [mm] 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.
Motor Description
20 Product Manual
Hub interfaces
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 type of fastening screws for hub interface.
Select the hub screws according to the wheel rim design.
Figure 13. Hub fastening screw variants.
BB series motors with static multi-disc brake
ØD2
ØD3
V1
ØD1
Figure 14. Dimensions of the hub interface.
3.6.3
Motor Description
Product Manual 21
INTERFACE DIMENSIONS BB 4 BB 5 BB 6 BB 7
Hub interface
D1 [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
D2 min. [mm] 161 221 281 371
V1 min. [mm] 1x45° 1x45° 1x45° 1x45°
D3 min. [mm] 278 342 408 512
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 wheel rim or the rotatable device is attached to the motor hub.
BBC series motors without brake
ØD2
ØD3
V1
ØD1
Figure 15. Dimensions of the hub interface.
Motor Description
22 Product Manual
INTERFACE DIMENSIONS BBC 02 BBC 03 BBC 05
Hub interface
D1 [mm] 225 275 335
pattern 5x72° 8x45° 10x36°
size M22x1,5 M20x1,5 M22x1,5
strength class
1)
10,9 10,9 10,9
tightening tor-
que
2)
[Nm]
728 540 728
D2 min. [mm] 176 221 281
V1 min. [mm] 1x45° 1x45° 1x45°
D3 min. [mm] 282 315 376
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 wheel rim or the rotatable device is attached to the motor hub.
BBC series motors with static multi-disc brake
ØD2
ØD3
V1
ØD1
Figure 16. Dimensions of the hub interface.
Motor Description
Product Manual 23
INTERFACE DIMENSIONS BBC 02 BBC 03 BBC 05
Hub interface
D1 [mm] 225 275 335
pattern 5x72° 8x45° 10x36°
size M22x1,5 M20x1,5 M22x1,5
strength class
1)
10,9 10,9 10,9
tightening tor-
que
2)
[Nm]
728 540 728
D2 min. [mm] 176 221 281
V1 min. [mm] 1x45° 1x45° 1x45°
D3 min. [mm] 282 315 376
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 wheel rim or the rotatable device is attached to the motor hub.
BBC series motors with double brake
ØD2
ØD3
V1
ØD1
Figure 17. Dimensions of the hub interface.
Motor Description
24 Product Manual
INTERFACE DIMENSIONS BBC 02 BBC 03
Hub interface
D1 [mm] 225 275
pattern 5x72° 8x45°
size M22x1,5 M20x1,5
strength class
1)
10,9 10,9
tightening tor-
que
2)
[Nm]
728 540
D2 min. [mm] 176 221
V1 min. [mm] 1x45° 1x45°
D3 min. [mm] 282 315
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 wheel rim or the rotatable device is attached to the motor hub.
Rotating direction
Figure 18. 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 BB motor and the ow direction in the working lines is
given in the table below.
Table 1: Rotating direction and ow direction of BB motors.
ROTATING DIRECTION
ow direction
A → B B → A
40DVVVY140 CW CCW
40DVVVY240 CW CCW
40DVVVY340 CCW CW
3.7
Motor Description
Product Manual 25
Preferred operating direction of BB motors
The preferred operating direction applies to BB motors with 2-speed valve.
The preferred operating direction is the rotating direction of the motor when the ow
direction is from port A to B.
• 2 = CW motor (For the right side of a vehicle.)
• 3 = CCW motor (For the left side of a vehicle.)
The rotating direction of the BBC motor and the ow direction in the working lines is
given in the table below.
Table 2: Rotating direction and ow direction of BBC motors.
ROTATING DIRECTION ow direction
A → B B → A
No preferred rotating
direction
CW CCW
Freewheeling
Hydrostatic freewheeling and mechanical freewheeling are options for BB and BBC
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 (all BB motors without ush port C1) between the motor and the
check valve.
Hydrostatic freewheeling of a multispeed BBC motor
In a multispeed (2- and 4-speed) BBC motor without freewheeling springs, the
freewheeling pressure is supplied to the motor case through case ushing line C1.
Multispeed BBC motor has an in-built check valve and thus no external check valve in
case drain line is required.
The freewheeling valve should be positioned as close to the motor as possible to
ensure smooth and rapid mode change.
3.8
3.8.1
Motor Description
26 Product Manual
Mechanical freewheeling
Figure 19. A piston with the freewheeling
spring.
The motors can be equipped with mechanical freewheeling springs, which enable the
motor disengagement. When there is no pressure in the working lines of the motor,
the springs push the pistons down into the cylinders and hold them there. When
disengaged the motor may be used without active uid supply from the hydraulic
system.
In systems using mechanical freewheeling, the drain line should be connected
directly to the reservoir to ensure the lowest possible case pressure.
To ensure there is no pressure dierential between the work lines A and B (acting
under the pistons) and case drain line C (over the pistons), the three (3) lines are to be
connected together in freewheel mode.
The external freewheeling valve should be positioned as close to the motor as
possible to ensure smooth and rapid mode change.
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 can be a separate external 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.
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.
3.8.2
Motor Description
Product Manual 27
Constant clattering of the pistons may cause premature wear or failure of
the motor.
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.
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.
The permissible freewheeling speeds can be found on the technical data (see 3.4
Technical data BB series and 3.5 Technical data BBC series).
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 a 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.
1-speed motors
BB motors BBC motors
40DVVVY140 CDV1E1Y0AA
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.
3.9
Motor Description
28 Product Manual
Figure 20. 1-speed motor. Figure 21. Hydraulic circuit, 1-speed motor.
Multi-speed motors
BB motors BBC motors
40DVVVY240 CDV2E1Y0AA
40DVVVY340 C5V7E1Y0AA
2-speed BB motors have preferred rotational direction at partial displacement.
Operating the BB motor at partial displacement for an extended time in the non-
preferred direction will lead into motor failure.
2- and 4-speed BBC motors do not have preferred rotational direction and can be
operated at maximum rated power in both directions.
In 2-speed BB and standard 2-speed BBC motors, a 15-30 bar control pressure to Y
port is required to activate 2-speed (partial displacement of a 2-speed motor).
Depressurizing the Y port will return the motor to full displacement. Do not use work/
high pressure in Y port to control a standard 2-speed BB or BBC motor.
BBC 05 4-speed motors have high pressure shift ports (Y1 and Y2). To shift such
motor, the highest available system pressure has to be applied to the shift port.
Typically this highest system pressure is taken from motor work lines A and B by a
shuttle valve.
3.10
Motor Description
Product Manual 29
A
B
C2
C1
Y
P
Figure 22. 2-speed BB motor.
A
Y
B
C2
C1
Figure 23. 2-speed BBC motor.
Attention:
Always use C2 port to connect the drain line of a multi-speed BBC motor.
C1 can only be used for ush oil or to install an accumulator into the motor.
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.
• 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 3.4
Technical data BB series and 3.5 Technical data BBC series).
Attention:
Continuous use of high working pressure in the working line B at half
displacement in BB 2-speed motors, may cause premature wear or failure
of the motor.
Note:
Depressurize the 2-speed spool pilot Y to case drain line to prevent
unwanted spool movement.
Motor Description
30 Product Manual
Seal protector and grease nipples
The seal protector is a standard feature in the BBC series motors (excluding the
double brake motors). The seal protector is also known as a grease ring.
The seal protector prevents dirt and moisture from entering to the motor shaft seal.
The operation of the seal protector is based on a sealing lubricant pocket.
Figure 24. BBC motor's seal protector and grease nipples.
Brakes
There is a variety of brakes available for Black Bruin motors. Brakes, like motors, are
designed in compact, powerful packages and tailored to meet the customer specic
requirements in various applications.
Static wet multi-disc brake for BBC and BB series motors
The spring applied, pressure to release, wet multi-disc brake is a parking brake, but it
can be used dynamically as an emergency brake.
For the minimum brake release pressure, refer to 3.4 Technical data BB series and 3.5
Technical data BBC series. The brake operating pressure in BBC (low pressure brake)
can not be higher than 30 bar. Depending on the Black Bruin frame size, the brake
may have internal leakage (max. 0.6 l/min with oil viscosity of 35 cSt), which has to
be considered in the brake circuit design. In BBC motors the brake can be manually
released for emergency towing.
Standard, high pressure, BB brakes are equipped with static seals and do not have
internal leakage. Note that EP, HD and some anti-wear additives in oil can cause
remarkable reduction in brake torque.
3.11
3.12
3.12.1
Motor Description
Product Manual 31
Figure 25. Static wet multi-disc brake
Double brake for BBC series motors
The double brake motor includes:
• A static wet multi-disc low pressure brake
• Spring applied, pressure to release, parking brake
• A dynamic multi-disc brake
• Pressure applied, spring release, service brake
• The ultimate brake for the most demanding conditions
• Cooling through ushing for dynamic use
• Well-sealed structure isolating the brake from the environment and the motor
from the brake
Figure 26. BBC motor's double brake
3.12.2
Motor Description
32 Product Manual
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.
Counter pressure operation
Counter pressure operation is needed mainly in series connection (see 4.4.1 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.
4
4.1
4.1.1
4.1.2
System Design
Product Manual 33
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 3.8.2
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
System Design
34 Product Manual
Hydraulic connections
Figure 28. The interface of the motor
hydraulics without a brake.
Figure 29. The interface of the motor
hydraulics with the double brake.
C2
Y
C1
A + B
Figure 30. The hydraulic connections of a
2-speed BBC motor without a brake.
C
Y
D
A + B
Figure 31. The hydraulic connections of a
2-speed BB motor with a brake.
4.2
System Design
Product Manual 35
C2
A + B
Y1
Y2
D
C1
Figure 32. The hydraulic connections of a
4-speed BBC 05 motor with a brake.
A + B
C1
D2a
D2b
D
F1
C2
Y
D2b
F2
Figure 33. The hydraulic connections of a
2-speed BBC 02 motor with the double
brake.
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 or C2) and CASE FLUSHING LINE PORT (C1)
The case drain line is the return line from the housing cavity.
Most of the Black Bruin motors are equipped with the case ushing line (C1). The
ushing line is an extra case line. From a charge pump, or an alternative source,
cool oil from reservoir is fed into motor housing through the ushing line (C1).
The case drain line is marked with C. Motors with case ushing line C1 have a case
drain line marked with C2. The case drain line is used for case drain and returning
ush oil. To ensure motor functionality, C1 line has to be either plugged or used for
ush ow in. C2 is always used for case drain ow out. Do not use C1 as case drain
line.
• BRAKE PRESSURE PORTS (D, D2a and D2b)
The motors with parking brake have brake release line marked with D.
BBC motors with double brake have service brake pilot lines marked with D2a and
D2b.
• BRAKE FLUSHING LINE PORTS (F1 and F2)
BBC motors with double brake have service brake ushing lines marked with F1
and F2.
• PILOT LINE PORTS (Y or Y1 and Y2)
The pilot line is meant for controlling a 2-speed or 4-speed motor (see 3.10 Multi-
speed motors).
Note:
The gures represent motor connections of specic models and are
therefore only suggestive. For detailed information consult the motor
manufacturer or its representatives.
System Design
36 Product Manual
External freewheeling valve
The external freewheeling valve is used for disengaging the motor during motion (see
3.8.2 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.
MECHANICAL FREEWHEELING, CHECK
VALVE
MECHANICAL FREEWHEELING, 2/2 VALVE
Min.
3 bar
A
B
C2
C1
*
Figure 34. Motor with mechanical free-
wheeling, external freewheeling valve and
check valve.
Min.
3 bar
A
B
C2
C1
Figure 35. Motor with mechanical free-
wheeling and a 2/2-valve to depressurize
work lines to case drain (open loop).
4.3
System Design
Product Manual 37
MECHANICAL FREEWHEELING, CLOSED
LOOP
HYDROSTATIC FREEWHEELING, OPEN
LOOP
A
B
C2
C1
Figure 36. Motor with mechanical free-
wheeling and external freewheeling valve
(closed loop).
Min.
3 bar*
A
B
C2
C1
0,5 bar
Figure 37. Motor with hydrostatic free-
wheeling and external freewheeling valve
(open loop).
System Design
38 Product Manual
HYDROSTATIC FREEWHEELING, CLOSED
LOOP
HYDROSTATIC FREEWHEELING FOR 2-
SPEED BBC
A
B
C2
C1
0,5 bar
Figure 38. Motor with hydrostatic free-
wheeling and external freewheeling valve
(closed loop).
Min.
3 bar
A
B
C2
Y1
C1
*
Figure 39. 2-speed BBC motor with hydro-
static freewheeling and external free-
wheeling valve in open loop system. Maxi-
mum case drain pressure 2 bar.
Hydraulic
uid
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
4.4.1
System Design
Product Manual 39
PARALLEL CIRCUIT
Figure 40. 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 41. A pilot controlled ow divider valve.
SERIES CIRCUIT
Figure 42. 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
40 Product Manual
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.
Make sure that the motor case is always full of oil.
4.4.2
4.4.3
4.4.4
4.5
4.5.1
System Design
Product Manual 41
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.
If motor is placed above the reservoir, add check valve with 1 bar (15 psi)
pressure to case drain line to ensure case oil ll. Maximum continuous
case pressure 2 bar.
Pilot pressure
BB motors BBC motors
404VVVY2/340 C2V2E1Y0AA
405VVVY2/340 C3V2E1Y0AA
406VVVY2/340 C5V2E1Y0AA
407VVVY2/340 C5V7E1Y0AA
The pilot pressure is used to engage the options of the multi-speed motors.
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 3.4
Technical data BB series and 3.5 Technical data BBC series):
• 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).
MAXIMUM PRESSURE
Unless governed by the power limit, oil temperature or oil viscosity, the maximum
pressure is the maximum continuous work pressure.
4.5.2
4.5.3
System Design
42 Product Manual
Motor life depends on average speed and pressure. The higher the pressure, the
shorter the expected life. For Lh10 calculations, please consult the manufacturer.
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
guarantees continuous contact between cam rollers and cam ring.
The minimum pressure is maintained with charge pressure. Type of the hydraulic
system aects the implementation.
• 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.
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.
Constant use with too low working line pressure may cause premature
wear or failure of the motor.
Note:
Minimum work line pressure values are given at zero case pressure. To
calculate system specic minimum pressure, add case pressure to the
minimum pressure value from the chart.
The required minimum pressure depends on the rotational speed and case pressure.
Recommended values for the minimum pressure at zero case pressure are on the
following gures:
System Design
Product Manual 43
BB series motors
WORKING LINE PRESSURE
[bar]
Figure 43. The minimum pressure at full displacement (uid vis-
cosity 35 cSt).
Flow rate
[l/min]
WORKING LINE PRESSURE
[bar]
Figure 44. The minimum pressure at half displacement (uid
viscosity 35 cSt).
Flow rate
[l/min]
System Design
44 Product Manual
BBC series motors
WORKING LINE PRESSURE
[bar]
Figure 45. The minimum pressure at full and half displacement
(uid viscosity 35 cSt).
Flow rate
[l/min]
System Design
Product Manual 45
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 46. 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 (excluding the 4-speed motors).
Figure 47. Motor orientation to the load direction.
5
5.1
5.1.1
Motor Sizing
46 Product Manual
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)
BB series motors:
BB 4:
BB 5:
BB 6:
BB 7:
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
BBC series motors:
BBC 2:
BBC 3:
BBC 5:
F
max
≥ α x F
r
+ 5,62 x r x F
a
F
max
≥ α x F
r
+ 5,41 x r x F
a
F
max
≥ α x F
r
+ 4,45 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
BB series motors
MOTOR LOAD CURVE: BB 4
F
max
[kN]
Figure 48. Motor load carrying capacity Fmax.
Wheel o-
set, a [mm]
MOTOR LOAD CURVE: BB 5, BB 6 AND BB 7
F
max
[kN]
Figure 49. Motor load carrying capacity Fmax.
Wheel o-
set, a [mm]
5.1.2
Motor Sizing
Product Manual 47
BBC series motors
MOTOR LOAD CURVE: BBC 02 AND BBC 03
F
max
[kN]
Figure 50. Motor load carrying capacity Fmax.
Wheel o-
set, a [mm]
MOTOR LOAD CURVE: BBC 05
F
max
[kN]
Figure 51. Motor load carrying capacity Fmax.
Wheel o-
set, a [mm]
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 endures 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]
F
r
= average wheel load [kN]
F
10m
= bearing load carrying capacity [kN]
5.1.3
Motor Sizing
48 Product Manual
BB series motors
BEARINGS LOAD CURVE: BB 4 and BB 5
Load
[kN]
Figure 52. Bearing load carrying capacity F10m.
Wheel o-
set, a[mm]
BEARINGS LOAD CURVE: BB 6 and BB 7
Load
[kN]
Figure 53. Bearing load carrying capacity F10m.
Wheel o-
set, a[mm]
BBC series motors
BEARINGS LOAD CURVE: BBC 02 and BBC 03
Load
[kN]
Figure 54. Bearing load carrying capacity F10m.
Wheel o-
set, a[mm]
Motor Sizing
Product Manual 49
BEARINGS LOAD CURVE: BBC 05
Load
[kN]
Figure 55. Bearing load carrying capacity F10m.
Wheel o-
set, a[mm]
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.
5.2
5.2.1
Motor Sizing
50 Product Manual
WORKING SPEED - WHEEL RADIUS
speed [rpm]
Figure 56. 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 57. 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 51
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
BB motors performance curves
BB 4
Torque
[Nm]
Figure 58. Perfomance curves BB 4,
630ccm (uid viscosity 35cSt).
Max. power
35 kW
Max. speed
240 rpm
Speed
[rpm]
5.2.3
5.3
5.3.1
Motor Sizing
52 Product Manual
Torque
[Nm]
Figure 59. Perfomance curves BB 4,
800ccm (uid viscosity 35cSt).
Max. power
35 kW
Max. speed
185 rpm
Speed
[rpm]
BB 5
Torque
[Nm]
Figure 60. Perfomance curves BB 5,
1000ccm (uid viscosity 35cSt).
Max. power
50 kW
Max. speed
200 rpm
Speed
[rpm]
Motor Sizing
Product Manual 53
Torque
[Nm]
Figure 61. Perfomance curves BB 5,
1250ccm (uid viscosity 35cSt).
Max. power
50 kW
Max. speed
160 rpm
Speed
[rpm]
Torque
[Nm]
Figure 62. Perfomance curves BB 5,
1600ccm (uid viscosity 35cSt).
Max. power
50 kW
Max. speed
125 rpm
Speed
[rpm]
Motor Sizing
54 Product Manual
BB 6
Torque
[kNm]
Figure 63. Perfomance curves BB 6,
2000ccm (uid viscosity 35cSt).
Max. power
90 kW
Max. speed
175 rpm
Speed
[rpm]
Torque
[kNm]
Figure 64. Perfomance curves BB 6,
2500ccm (uid viscosity 35cSt).
Max. power
90 kW
Max. speed
140 rpm
Speed
[rpm]
Motor Sizing
Product Manual 55
Torque
[kNm]
Figure 65. Perfomance curves BB 6,
3150ccm (uid viscosity 35cSt).
Max. power
90 kW
Max. speed
110 rpm
Speed
[rpm]
BB 7
Torque
[kNm]
Figure 66. Perfomance curves BB 7,
4000ccm (uid viscosity 35cSt).
Max. power
130 kW
Max. speed
125 rpm
Speed
[rpm]
Motor Sizing
56 Product Manual
Torque
[kNm]
Figure 67. Perfomance curves BB 7,
5000ccm (uid viscosity 35cSt).
Max. power
130 kW
Max. speed
100 rpm
Speed
[rpm]
Torque
[kNm]
Figure 68. Perfomance curves BB 7,
6300ccm (uid viscosity 35cSt).
Max. power
130 kW
Max. speed
80 rpm
Speed
[rpm]
Motor Sizing
Product Manual 57
BBC motors performance curves
BBC 02
Torque
[Nm]
Figure 69. Perfomance curves BBC 02,
705ccm (uid viscosity 35cSt).
Max. power
42 kW
Max. speed
223 rpm
Speed
[rpm]
Torque
[Nm]
Figure 70. Perfomance curves BBC 02,
862ccm (uid viscosity 35cSt).
Max. power
42 kW
Max. speed
182 rpm
Speed
[rpm]
5.3.2
Motor Sizing
58 Product Manual
Torque
[Nm]
Figure 71. Perfomance curves BBC 02,
1018ccm (uid viscosity 35cSt).
Max. power
42 kW
Max. speed
151 rpm
Speed
[rpm]
BBC 03
Torque
[Nm]
Figure 72. Perfomance curves BBC 03,
909ccm (uid viscosity 35cSt).
Max. power
50 kW
Max. speed
206 rpm
Speed
[rpm]
Motor Sizing
Product Manual 59
Torque
[Nm]
Figure 73. Perfomance curves BBC 03,
1111ccm (uid viscosity 35cSt).
Max. power
50 kW
Max. speed
169 rpm
Speed
[rpm]
Torque
[Nm]
Figure 74. Perfomance curves BBC 03,
1313ccm (uid viscosity 35cSt).
Max. power
50 kW
Max. speed
143 rpm
Speed
[rpm]
Motor Sizing
60 Product Manual
BBC 05
Torque
[Nm]
Figure 75. Perfomance curves BBC 05,
1572ccm (uid viscosity 35cSt).
Max. power
72 kW
Max. speed
172 rpm
Speed
[rpm]
Torque
[Nm]
Figure 76. Perfomance curves BBC 05,
1922ccm (uid viscosity 35cSt).
Max. power
72 kW
Max. speed
141 rpm
Speed
[rpm]
Motor Sizing
Product Manual 61
Torque
[Nm]
Figure 77. Perfomance curves BBC 05,
2271ccm (uid viscosity 35cSt).
Max. power
72 kW
Max. speed
119 rpm
Speed
[rpm]
BB motors case leakage
[l/min]
Figure 78. Case leakage curves of BB series motors (uid viscos-
ity 35 cSt).
Pressure
[bar]
5.3.3
Motor Sizing
62 Product Manual
BBC motors case leakage
[l/min]
Figure 79. Case leakage curves of BBC series motors (uid vis-
cosity 35 cSt).
Pressure
[bar]
5.3.4
Motor Sizing
Product Manual 63
Installation Instructions
Conditions of installation and application
An Application Data Sheet (ADS) is used to select the correct Black Bruin hydraulic
motor for each application. A lled and signed ADS is required for each motor model
and application to validate the motor manufacturer’s warranty. Always advise the
motor manufacturer or its representative, when selecting motors for exceptional
circumstances, like underwater applications, use with special uids, etc.
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 80. 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.
6
6.1
6.2
6.3
Installation Instructions
64 Product Manual
Hydraulic connections
Warning:
Do not apply the working pressure to the case drain line port (C, C1 or C2).
This can break the motor.
Before you make any hydraulic connections to the motor, examine the motor product
datasheet for the correct hydraulic connections.
Air bleeding procedure
1
2
Air bleeding procedure is carried out to
ll the motor case completely with hydraulic
uid. Air is removed from the motor case with the air bleed screws as follows:
• Locate the air bleed screws on the hub cover (1) or rear cover (2). Turn the motor
to a position in which the bleed screw is at its topmost position.
• Make sure the drain line of the motor is connected.
• Feed hydraulic uid into the motor with low pressure throughout the procedure
(with system charge pressure or ow through the case drain line).
• Unscrew the air bleed screw by half a turn and wait for the air to bleed out.
• Close the screw when only hydraulic uid is pouring through it.
Note:
If charge pressure is not available (open loop) or return ow through drain
line is prevented, ll the case manually by pouring oil in through the bleed
screw hole.
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:
• At the initial startup, start the motor without a load.
• Do not run the motor immediately with full power. Increase the load and speed of
rotation gradually.
6.4
6.5
6.6
Installation Instructions
Product Manual 65
• Observe the motor and the hydraulic system for external leaks or abnormal noises
during the commissioning procedure.
• Start the motor break-in. Refer to 7.1 Break-in period.
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.
Note:
During all installation and service procedures, plug any open ports and
hoses.
When lling the reservoir, add hydraulic uid through a lter.
Tightening torques
SCREW / HARDNESS HUB COVER, f10.9 (Nm) SHAFT FLANGE, f12.9 (Nm)
M12 110 135
M14 180 215
M16 275 330
M18 383 460
M20 540 650
M22 728 874
The tightening torques are valid for standard and ne thread.
Note:
The maximum torque can be limited at lower value by the motor
attachment.
6.7
Installation Instructions
66 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 the rst eight hours (8 h) of use.
• Operate the motors at average of 50% of rated speed and pressure.
• Limit the power output by limiting the working pressure, the speed of rotation or
both.
• Do not exceed 75% of the maximum pressure for more than two seconds every
minute.
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.
• Clean the outside of the motor thoroughly, but do not use any solvents.
7
7.1
7.2
7.3
7.4
Operating Instructions
Product Manual 67
• 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
68 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 69
70 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 20230606