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Black Bruin BB series Product Manual

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BB and BBC series

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  • Page 1 Product Manual BB and BBC series...

  • Page 2: Table Of Contents

    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 System Design................. 33 Motor hydraulic circuit..........................33 4.1.1 Simple connection........................33 4.1.2...
  • Page 3 Contents Motor Sizing..................46 Load carrying capacity..........................46 5.1.1 Wheel offset..........................46 5.1.2 Allowed wheel load........................47 5.1.3 Service life............................ 48 Performance..............................50 5.2.1 Rotating speed and flow rate....................50 5.2.2 Torque............................. 51 5.2.3 Power............................. 52 Performance charts............................52 5.3.1 BB motors performance curves....................52 5.3.2 BBC motors performance curves...................58 5.3.3...

  • Page 4: General Instructions

    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.

  • Page 5: Publication Date

    General Instructions Publication date 26.04.2019 - This manual is published. Declaration of incorporation Product Manual...

  • Page 6: Safety Instructions

    Safety Instructions 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.

  • Page 7: Motor Description

    Motor Description 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. Shaft Distribution valve Cylinder block Piston Cam roll Cam ring Bearings Housing 10.

  • Page 8: Motor Model Code Bb Series

    Motor Description Motor model code BB series BB SERIES MODEL CODE 40DVVVYW40 Hydraulic motors with parking brake 40DVVVYW40 BB series standard code D: Motor frame size 40DVVVYW40 BB 4 BB 5 BB 6 BB 7 BB 4: 630-800 ccm ●...

  • Page 9: Motor Model Code Bbc Series

    Motor Description Code example 4051602140 The motor with a wet multi-disc parking brake The motor is a standard motor Motor model code BBC series BBC SERIES MODEL CODE CDVWE1Y0AA Hydraulic motors CDVWE1Y0AA BBC series standard code D: Motor frame size CDVWE1Y0AA BBC 02 BBC 03...

  • Page 10: Technical Data Bb Series

    The motor with a wet multi-disc parking brake The motor with a case flushing line The motor with mechanical freewheeling AA = The motor is a standard motor Technical data BB series TECHNICAL DATA BB 4 BB 5 Displacement [ccm]...
  • Page 11 Motor Description TECHNICAL DATA BB 4 BB 5 releasing pressure [bar] brake pressure (max.) [bar] needed oil volume [ccm] Weight [kg] 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...

  • Page 12: Technical Data Bbc Series

    Motor Description Brake torque for new brake. Technical data BBC series TECHNICAL DATA BBC 02 BBC 03 Displacement [ccm] 1018 1111 1313 Maximum torque [Nm] peak torque 4645 5680 5965 5990 7320 7690 intermittent 4130 5050 5220 5325 6510 6730 Max.
  • Page 13 Motor Description TECHNICAL DATA BBC 02 BBC 03 with parking brake with double brake 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 at 3/4 displacement at half displacement at 1/4 displacement...

  • Page 14: Motor Interfaces

    If pilot pressure over 30 bar is used, the pilot line should be throttled. Brake torque for new brake. Motor interfaces 3.6.1 Main dimensions BB series motors with static multi-disc brake Figure 5. Main dimensions of the motor. MAIN DIMENSIONS BB 4 BB 5...
  • Page 15 Motor Description BBC series motors without brake Figure 6. Main dimensions of the motor. MAIN DIMENSIONS BBC 02 BBC 03 BBC 05 Motor [mm] [mm] [mm] BBC series motors with static multi-disc brake Figure 7. Main dimensions of the motor. Product Manual...

  • Page 16: Shaft Interfaces

    Motor Description MAIN DIMENSIONS BBC 02 BBC 03 BBC 05 Motor [mm] [mm] [mm] BBC series motors with double brake Figure 8. Main dimensions of the motor. MAIN DIMENSIONS BBC 02 BBC 03 Motor [mm] [mm] [mm] 3.6.2 Shaft interfaces The motor is attached to the body of the vehicle or device from the shaft flange.
  • Page 17 Motor Description BB series motors with static multi-disc brake Figure 9. Dimensions of the shaft interface. INTERFACE DIMENSIONS BB 4 BB 5 BB 6 BB 7 Shaft interface [mm] pattern 6x60° 8x45° 12x30° 16x22,5° size M16x2,0 M16x2,0 M20x1,5 M20x1,5 strength class...
  • Page 18 Motor Description BBC series motors without brake Figure 10. Dimensions of the shaft interface. INTERFACE DIMENSIONS BBC 02 BBC 03 BBC 05 Shaft interface [mm] pattern 8x45° 10x36° 12x30° size M16x2,0 M16x2,0 M20x1,5 strength class 12,9 12,9 12,9 tightening tor- [Nm] min.
  • Page 19 Motor Description BBC series motors with static multi-disc brake Figure 11. Dimensions of the shaft interface. INTERFACE DIMENSIONS BBC 02 BBC 03 BBC 05 Shaft interface [mm] pattern 8x45° 10x36° 12x30° size M16x2,0 M16x2,0 M20x1,5 strength class 12,9 12,9 12,9 tightening tor- [Nm] min.
  • Page 20 Motor Description BBC series motors with double brake Figure 12. Dimensions of the shaft interface. INTERFACE DIMENSIONS BBC 02 BBC 03 Shaft interface [mm] pattern 8x45° 10x36° size M16x2,0 M16x2,0 strength class 12,9 12,9 tightening tor- [Nm] min. [mm] min. [mm] max.

  • Page 21: Hub Interfaces

    There are multiple different 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 Figure 14. Dimensions of the hub interface. Product Manual...
  • Page 22 Motor Description INTERFACE DIMENSIONS BB 4 BB 5 BB 6 BB 7 Hub interface [mm] pattern 6x60° 8x45° 10x36° 12x30° size M18x1,5 M20x1,5 M22x1,5 M22x1,5 strength class 10,9 10,9 10,9 10,9 tightening tor- [Nm] min. [mm] min. [mm] 1x45° 1x45° 1x45°...
  • Page 23 Motor Description INTERFACE DIMENSIONS BBC 02 BBC 03 BBC 05 Hub interface [mm] pattern 5x72° 8x45° 10x36° size M22x1,5 M20x1,5 M22x1,5 strength class 10,9 10,9 10,9 tightening tor- [Nm] min. [mm] min. [mm] 1x45° 1x45° 1x45° min. [mm] Strength class as in ISO898-1. If using lower strength class, check interface load capacity and tightening torque.
  • Page 24 Motor Description INTERFACE DIMENSIONS BBC 02 BBC 03 BBC 05 Hub interface [mm] pattern 5x72° 8x45° 10x36° size M22x1,5 M20x1,5 M22x1,5 strength class 10,9 10,9 10,9 tightening tor- [Nm] min. [mm] min. [mm] 1x45° 1x45° 1x45° min. [mm] Strength class as in ISO898-1. If using lower strength class, check interface load capacity and tightening torque.

  • Page 25: Rotating Direction

    Motor Description INTERFACE DIMENSIONS BBC 02 BBC 03 Hub interface [mm] pattern 5x72° 8x45° size M22x1,5 M20x1,5 strength class 10,9 10,9 tightening tor- [Nm] min. [mm] min. [mm] 1x45° 1x45° min. [mm] Strength class as in ISO898-1. If using lower strength class, check interface load capacity and tightening torque.

  • Page 26: 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.

  • Page 27: Mechanical Freewheeling

    Motor Description 3.8.2 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 fluid supply from the hydraulic system.

  • Page 28: 1-Speed Motors

    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 Technical data BB series on page 10 and Technical data BBC series on page 12).

  • Page 29: Multi-Speed Motors

    Motor Description Figure 20. 1-speed motor. Figure 21. Hydraulic circuit, 1-speed motor. 3.10 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.
  • Page 30 • Prevent operating conditions, in which the permissible performance values could be exceeded. The permissible performance values are in the technical data (see Technical data BB series on page 10 and Technical data BBC series page 12).

  • Page 31: Seal Protector And Grease Nipples

    Figure 24. BBC motor's seal protector and grease nipples. 3.12 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 specific requirements in various applications.

  • Page 32: Double Brake For Bbc Series Motors

    Motor Description Figure 25. Static wet multi-disc brake 3.12.2 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 •...

  • Page 33: System Design

    System Design System Design Motor hydraulic circuit 4.1.1 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 figure above. •...

  • Page 34: Hydrostatic Braking

    System Design Counter pressure operation is not recommended, because high back pressure stresses the motor more than usual operation. 4.1.3 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.

  • Page 35: Hydraulic Connections

    System Design Hydraulic connections Figure 28. The interface of the motor Figure 29. The interface of the motor hydraulics without a brake. hydraulics with the double brake. A + B A + B Figure 30. The hydraulic connections of a Figure 31.
  • Page 36 The case drain line is the return line from the housing cavity. Most of the Black Bruin motors are equipped with the case flushing line (C1). The flushing 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 flushing line (C1).

  • Page 37: External Freewheeling Valve

    System Design External freewheeling valve The external freewheeling valve is used for disengaging the motor during motion (see Mechanical freewheeling on page 27). The freewheeling valve should be normally open, so that the motor will disengage when the control system is off. 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.
  • Page 38 System Design MECHANICAL FREEWHEELING, CLOSED HYDROSTATIC FREEWHEELING, OPEN LOOP LOOP 0,5 bar Min. 3 bar* Figure 36. Motor with mechanical free- Figure 37. Motor with hydrostatic free- wheeling and external freewheeling valve wheeling and external freewheeling valve (closed loop). (open loop). Product Manual...

  • Page 39: Hydraulic Fluid

    System Design HYDROSTATIC FREEWHEELING, CLOSED HYDROSTATIC FREEWHEELING FOR 2- LOOP SPEED BBC 0,5 bar Min. 3 bar Figure 39. 2-speed BBC motor with hydro- static freewheeling and external free- Figure 38. Motor with hydrostatic free- wheeling valve in open loop system. Maxi- wheeling and external freewheeling valve mum case drain pressure 2 bar.
  • Page 40 System Design 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 flow rate and pressure. Note: The flow 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.

  • Page 41: Hydraulic Fluid Type

    4.4.2 Hydraulic fluid type Black Bruin hydraulic motors are designed to work with hydraulic fluids based on mineral oil. Consider the following requirements when choosing hydraulic fluid: • Hydraulic oils in accordance with ISO 6743-4 are recommended to be used.

  • Page 42: Pilot 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 BB series on page 10 and Technical data BBC series on page 12): •...
  • Page 43 System Design 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.
  • Page 44 System Design BB series motors WORKING LINE PRESSURE [bar] Flow rate [l/min] Figure 43. The minimum pressure at full displacement (fluid vis- cosity 35 cSt). WORKING LINE PRESSURE [bar] Flow rate [l/min] Figure 44. The minimum pressure at half displacement (fluid vis- cosity 35 cSt).
  • Page 45 System Design BBC series motors WORKING LINE PRESSURE [bar] Flow rate [l/min] Figure 45. The minimum pressure at full and half displacement (fluid viscosity 35 cSt). Product Manual...

  • Page 46: Motor Sizing

    Motor Sizing Motor Sizing Load carrying capacity 5.1.1 Wheel offset The load carrying capacity of the motor is defined by the offset value (a) of the wheel rim and the application specific safety factor. The offset value is the distance from the wheel center line (CL) to the motor shaft interface.

  • Page 47: Allowed Wheel Load

    With applications combining high radial and axial loads, please consult the motor manufacturer or its representative to determine maximum permissible loading. BB series motors: BB 4: ≥ α x F + 5,3 x r x F BB 5: ≥...

  • Page 48: Service Life

    Motor Sizing BBC series motors MOTOR LOAD CURVE: BBC 02 AND BBC 03 [kN] Wheel off- set, a [mm] Figure 50. Motor load carrying capacity Fmax. MOTOR LOAD CURVE: BBC 05 [kN] Wheel off- set, a [mm] Figure 51. Motor load carrying capacity Fmax. 5.1.3 Service life The service life of the motor is based on the rated life of its bearings.
  • Page 49 Motor Sizing BB series motors BEARINGS LOAD CURVE: BB 4 and BB 5 Load [kN] Wheel off- set, a[mm] Figure 52. Bearing load carrying capacity F10m. BEARINGS LOAD CURVE: BB 6 and BB 7 Load [kN] Wheel off- set, a[mm] Figure 53.

  • Page 50: Performance

    Motor Sizing BEARINGS LOAD CURVE: BBC 05 Load [kN] Wheel off- set, a[mm] Figure 55. Bearing load carrying capacity F10m. Performance 5.2.1 Rotating speed and flow rate Rotating speed of the motor and required flow rate may be calculated with the following equations: ROTATING SPEED RPM = rotating speed [rpm]...

  • Page 51: Torque

    Motor Sizing WORKING SPEED - WHEEL RADIUS speed [rpm] speed [km/h] speed [m/s] Figure 56. Vehicle speed and motor rotat- ing speed with different wheel radius. FREEWHEELING SPEED - WHEEL RADIUS speed [rpm] speed [km/h] speed [m/s] Figure 57. Vehicle freewheeling speed and motor rotating speed with different wheel radius.

  • Page 52: Power

    Motor Sizing MAXIMUM TORQUE T = torque [Nm] V = displacement [ccm] STARTUP TORQUE Δp = pressure difference [bar] 5.2.3 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 = flow rate in working lines [l/min] RPM = rotating speed [rpm]...
  • Page 53 Motor Sizing Torque Max. power [Nm] 35 kW Max. speed 185 rpm Speed [rpm] Charge pressure [bar] Figure 59. Perfomance curves BB 4, 800ccm (fluid viscosity 35cSt). BB 5 Torque Max. power [Nm] 50 kW Max. speed 200 rpm Speed [rpm] Charge pressure [bar]...
  • Page 54 Motor Sizing Torque Max. power [Nm] 50 kW Max. speed 160 rpm Speed [rpm] Charge pressure [bar] Figure 61. Perfomance curves BB 5, 1250ccm (fluid viscosity 35cSt). Torque Max. power [Nm] 50 kW Max. speed 125 rpm Speed [rpm] Charge pressure [bar] Figure 62.
  • Page 55 Motor Sizing BB 6 Torque Max. power [kNm] 90 kW Max. speed 175 rpm Speed [rpm] Charge pressure [bar] Figure 63. Perfomance curves BB 6, 2000ccm (fluid viscosity 35cSt). Torque Max. power [kNm] 90 kW Max. speed 140 rpm Speed [rpm] Charge pressure [bar]...
  • Page 56 Motor Sizing Torque Max. power [kNm] 90 kW Max. speed 110 rpm Speed [rpm] Charge pressure [bar] Figure 65. Perfomance curves BB 6, 3150ccm (fluid viscosity 35cSt). BB 7 Torque Max. power [kNm] 130 kW Max. speed 125 rpm Speed [rpm] Charge pressure [bar]...
  • Page 57 Motor Sizing Torque Max. power [kNm] 130 kW Max. speed 100 rpm Speed [rpm] Charge pressure [bar] Figure 67. Perfomance curves BB 7, 5000ccm (fluid viscosity 35cSt). Torque Max. power [kNm] 130 kW Max. speed 80 rpm Speed [rpm] Charge pressure [bar] Figure 68.

  • Page 58: Bbc Motors Performance Curves

    Motor Sizing 5.3.2 BBC motors performance curves BBC 02 Torque Max. power [Nm] 42 kW Max. speed 223 rpm Speed [rpm] Charge pressure [bar] Figure 69. Perfomance curves BBC 02, 705ccm (fluid viscosity 35cSt). Torque Max. power [Nm] 42 kW Max.
  • Page 59 Motor Sizing Torque Max. power [Nm] 42 kW Max. speed 151 rpm Speed [rpm] Charge pressure [bar] Figure 71. Perfomance curves BBC 02, 1018ccm (fluid viscosity 35cSt). BBC 03 Torque Max. power [Nm] 50 kW Max. speed 206 rpm Speed [rpm] Charge pressure [bar]...
  • Page 60 Motor Sizing Torque Max. power [Nm] 50 kW Max. speed 169 rpm Speed [rpm] Charge pressure [bar] Figure 73. Perfomance curves BBC 03, 1111ccm (fluid viscosity 35cSt). Torque Max. power [Nm] 50 kW Max. speed 143 rpm Speed [rpm] Charge pressure [bar] Figure 74.
  • Page 61 Motor Sizing BBC 05 Torque Max. power [Nm] 72 kW Max. speed 172 rpm Speed [rpm] Charge pressure [bar] Figure 75. Perfomance curves BBC 05, 1572ccm (fluid viscosity 35cSt). Torque Max. power [Nm] 72 kW Max. speed 141 rpm Speed [rpm] Charge pressure [bar]...

  • Page 62: Bb Motors Case Leakage

    119 rpm Speed [rpm] Charge pressure [bar] Figure 77. Perfomance curves BBC 05, 2271ccm (fluid viscosity 35cSt). 5.3.3 BB motors case leakage [l/min] Pressure [bar] Figure 78. Case leakage curves of BB series motors (fluid viscos- ity 35 cSt). Product Manual...

  • Page 63: Bbc Motors Case Leakage

    Motor Sizing 5.3.4 BBC motors case leakage [l/min] Pressure [bar] Figure 79. Case leakage curves of BBC series motors (fluid vis- cosity 35 cSt). Product Manual...

  • Page 64: Installation Instructions

    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 filled 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 fluids, etc.

  • Page 65: Hydraulic Connections

    Installation Instructions 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 Air bleeding procedure is carried out to fill the motor case completely with hydraulic fluid.

  • Page 66: Tightening Torques

    Installation Instructions • Observe the motor and the hydraulic system for external leaks or abnormal noises during the commissioning procedure. • Start the motor break-in. Refer to Break-in period on page 67. Attention: Do not start the motor, if the air bleeding procedure has not been carried out.

  • Page 67: Operating Instructions

    Operating Instructions Operating Instructions Break-in period The motor achieves its final properties during the first 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 first eight hours (8 h) of use. •...
  • Page 68 Operating Instructions • 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. Product Manual...

  • Page 69: Special Instructions

    Special Instructions 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. •...
  • Page 70 +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.

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