Black Bruin B240, Product Manual

Page 1: ...Product Manual B200 series ...

Page 2: ...ical freewheeling 19 3 7 1 speed 1N00 20 3 8 2 speed valve 2N0R 2N0L 21 3 9 Freewheeling valve FW10 FW20 22 3 10 Seal protector NZ GZ 24 3 10 1 Fittings for one time lubrication 24 3 10 2 Fittings for regular lubrication 24 4 System Design 26 4 1 Motor hydraulic circuit 26 4 1 1 Simple connection 26 4 1 2 Motors in parallel or series circuit 26 4 1 3 Counter pressure operation 28 4 1 4 Hydrostatic...

Page 3: ... 2 2 Torque 37 5 2 3 Power 38 6 Installation Instructions 39 6 1 Mounting the motor 39 6 2 Flushing the hydraulic system 39 6 3 Air bleeding procedure 39 6 4 Commissioning procedure 40 7 Operating Instructions 41 7 1 Break in period 41 7 2 Use 41 7 3 Operating temperature 41 7 4 Demounting the motor 41 8 Special Instructions 43 8 1 Storing the motor 43 Contents Product Manual 3 ...

Page 4: ... working equipment 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 pr...

Page 5: ...Declaration of incorporation 1 6 General Instructions Product Manual 5 ...

Page 6: ...gnetic 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 fluid when disconnecting the hydrau...

Page 7: ...to the distribution valve The distribution valve directs the flow 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 flow to the pistons and switches the pistons to a return ...

Page 8: ...lacements 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 CCCC D B240 B250 B260 B270 1 speed 1N00 Fixed displacement 2 speed valve 2N0R Right side CW preferred 2N0L Left side CCW preferred Freewheeling valve FW10 Ty...

Page 9: ...ntrol The motor is CCW preferred in 2 speed mode D The seal protector of the motor is fitted for regular lubrication Processing ID B200 SERIES PROCESSING ID R M S P D T R M S P D T Lubrication Definition of factory lubrication 0 Seal protector is not filled with lubricant 1 1 Seal protector is filled with lubricant R M S P D T Painting Definition of the painted surfaces 0 No painting Motors are wa...

Page 10: ... equivalent Tint glossy black 3 Pressure openings and threaded holes are capped with plastic fittings Hydraulic fluid 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 630 800 1000 1250 1600 at half displacement 315 400 500 625 800 Maximum torqu...

Page 11: ... 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 half displacement 54 80 Max rotating speed rpm at full displacement 175 140 110 125 100 80 at half 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 Brake torque Nm ...

Page 12: ...and or certification 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 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...

Page 13: ... 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 specific tightening torques when given 3 Free space for hydraulic connections 4 Recommended feature to su...

Page 14: ...NSIONS 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 161 221 281 381 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 torq...

Page 15: ...hment screws are not included in the motor delivery Ensure correct dimensioning and availability of the hub screws There are multiple different type 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 Product Manual 15 ...

Page 16: ...se application specific 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 or a speed sensor pulse ring Figure 10 The motor with a disc brake Figure 11 The motor with a pulse sensor Note If necessary the grease nipples and plugs of the seal protector can be removed temporarily...

Page 17: ... 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 5 Motor Description Product Manual 17 ...

Page 18: ...ecific tightening torques when given Rotating direction Figure 14 Rotating direction of the motor The rotating direction of the motor is defined as the rotating direction of the housing viewed from the hub to the shaft The rotating direction of the motor and the flow direction in the working lines is given in the table below Table 1 Rotating direction and flow direction ROTATING DIRECTION flow dir...

Page 19: ...ement during motion is done with a freewheeling valve The freewheeling valve may be in built to the motor see Freewheeling valve FW10 FW20 on page 22 or a separate external valve see External freewheeling valve on page 29 which connects the working lines A and B and the case drain line C together The purpose of the valve is to remove pressure difference over the motor pistons This allows the pisto...

Page 20: ...DELAY While the pistons are retracting there is a momentary flow of hydraulic fluid 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 fluid should have as open channel as possible The external freewheeling valve should be positioned as close to the motor as ...

Page 21: ...function is a more extensive speed range with the same hydraulic system capacity The motors are also known as 2 speed motors Figure 18 2 speed motor Figure 19 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 fluid circulation in the motor 3 8 Motor Description Produ...

Page 22: ...ake the following things into consideration when changing the speed range during motion Hydraulic system supply must adjust to the rapid change of flowrate The rapid change in flow 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...

Page 23: ...he 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 ...

Page 24: ...grease ring Fittings for one time lubrication AAAA BBBB CCCC NZ R M S P D T The lubricating nipples and relief valve are replaced with plugs to prevent adding lubricant Fittings for regular lubrication AAAA BBBB CCCC GZ R M S P D T The seal protector has nipples to increase the lubricant and a relief valve to prevent overpressure More specific locations of these are indicated on the product datash...

Page 25: ...t is filled 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 flows 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 Product identification code...

Page 26: ...n 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 significantly if the motor is completely plugged during use Note Using the motor on a closed loop hydraulic system is different from the open loop system The closed loop system is more complex but enables more functions such as hydrostatic braking series conne...

Page 27: ...rdinary flow divider valve can not be used in most cases because its resistance of flow increases too much as the speed of the vehicle increases The flow distribution is usually required only when starting to move the vehicle A reliable solution is a flow divider valve which can be bypassed or switched on when necessary Figure 26 A pilot controlled flow divider valve SERIES CIRCUIT Figure 27 Two m...

Page 28: ...ine The minimum pressure and feed flow must be maintained in the feed line of the motor during hydrostatic braking Note The hydrostatic braking requires an active hydraulic fluid 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 indefinitely This leads to danger if a hydraulic ...

Page 29: ...d or freewheeling valve of the motor see 2 speed valve 2N0R 2N0L on page 21 and Freewheeling valve FW10 FW20 on page 22 External freewheeling valve The external freewheeling valve is used for disengaging the motor during motion see Mechanical freewheeling on page 19 The freewheeling valve should be normally open so that the motor will disengage when the control system is off When the motor is dise...

Page 30: ... may be necessa ry 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 freewheeling valve 6b This prevents case pressure peak caused by working pressure Figure 31 Freewheeling circuit with a 4 2 valve 6 2 VALVE With the 6 2 valve 6c the motor may be disengaged using ...

Page 31: ...dditives improving the viscosity index can decrease during operation Note Temperature has a significant effect on the viscosity and the lubricating capability of the hydraulic fluid Take into consideration the real operating temperature when defining the fluid viscosity The need for service and the overall service life may be improved by using hydraulic fluids with higher viscosity In addition hig...

Page 32: ...ze 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 Technical data on page 10 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 unde...

Page 33: ...working lines Recommended values for the minimum pressure are on the following figures WORKING LINE PRESSURE bar Figure 33 The minimum pressure at full displacement fluid viscosity 35 cSt bar Flow rate l min WORKING LINE PRESSURE bar Figure 34 The minimum pressure at half displacement fluid viscosity 35 cSt bar Flow rate l min Attention Too low pressure in the working lines causes the pistons to d...

Page 34: ...e given as a function of offset value The given load curves refer to the average wheel load on a single motor Figure 35 Negative and positive offset CL Center line M Motor side b Negative offset b 0 Zero offset b Positive offset Note Positive wheel offset allows significantly higher wheel loads Attention The motor load carrying capacity is applicable when the C port is orientated to the load direc...

Page 35: ...el load may be defined by the following equation s safety factor G average wheel load kN Fmax motor load carrying capacity kN If safety factor is predefined the allowed wheel load may be estimated with the following equation s safety factor Gmax allowed wheel load kN Fmax motor load carrying capacity kN Service life The service life of the motor is based on the rated life of its bearings The beari...

Page 36: ...city kN Performance Rotating speed and flow rate Rotating speed of the motor and required flow 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 flow 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...

Page 37: ...ed rpm Figure 40 Vehicle freewheeling speed and motor rotating speed with different wheel radius speed km h speed m s Torque The output torque of the motor is generated by the pressure difference of the working lines pressure difference between ports A and B The output torque of the motor may be estimated with the following equations 5 2 2 Motor Sizing Product Manual 37 ...

Page 38: ...operating conditions The operating power may be calculated with the following equation P power kW Q flow rate in working lines l min RPM rotating speed rpm V displacement ccm pw working pressure bar or Note Rough estimate of the operating power may be checked by dividing the available hydraulic power between the motors 5 2 3 Motor Sizing 38 Product Manual ...

Page 39: ... the nut Figure 41 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 flushed by circulating hydraulic fluid through a filter installed in place of the motor The flushing is carried out by circulating hydraulic fluid through the entire system with a minimum pressure for at least an hour Af...

Page 40: ...otor is flushed 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 duri...

Page 41: ...t flange 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 ...

Page 42: ...oroughly but do not use any solvents Protect the cleaned motor from corrosion If possible drain all the hydraulic fluid from the motor Note Dispose of hydraulic fluid should be done appropriately Operating Instructions 42 Product Manual ...

Page 43: ...ids alkalis and salts The motor should not be exposed to strong magnetic fields 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 fluid If these instructio...

Page 44: ...1 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 ...