Product Manual

B200 series
Contents

Contents

1 General Instructions......................................................................... 4
1.1 About the manual............................................................................................................................................4
1.2 Intended use..................................................................................................................................................... 4
1.3 Warranty............................................................................................................................................................. 4
1.4 Product identification..................................................................................................................................... 4
1.5 Revision comments.........................................................................................................................................4
1.6 Declaration of incorporation......................................................................................................................... 5

2 Safety Instructions........................................................................... 6
2.1 Warning symbols..............................................................................................................................................6

3 Motor Description.............................................................................. 7
3.1 Working principle.............................................................................................................................................. 7
3.2 Product identification code...........................................................................................................................8
3.2.1 Motor model code......................................................................................................................... 8
3.2.2 Processing ID................................................................................................................................. 9
3.3 Technical data.................................................................................................................................................10
3.4 Motor interfaces............................................................................................................................................. 12
3.4.1 Main dimensions.......................................................................................................................... 12
3.4.2 Shaft interface............................................................................................................................. 13
3.4.3 Hub interface................................................................................................................................14
3.4.4 Housing interface........................................................................................................................ 15
3.4.5 Drum brake interface.................................................................................................................. 17
3.5 Rotating direction.......................................................................................................................................... 18
3.6 Mechanical 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 braking.................................................................................................................... 28
4.1.5 Short circuit operation...............................................................................................................28
4.2 Hydraulic connections................................................................................................................................. 29
4.3 External freewheeling valve....................................................................................................................... 29
4.4 Hydraulic fluid................................................................................................................................................. 31
4.4.1 Hydraulic fluid type..................................................................................................................... 31
4.4.2 Hydraulic fluid properties.......................................................................................................... 31
4.4.3 Hydraulic fluid cleanliness.........................................................................................................31
4.5 Operating pressures...................................................................................................................................... 31
4.5.1 Case pressure............................................................................................................................... 31
4.5.2 Pilot pressure............................................................................................................................... 32
4.5.3 Working line pressure.................................................................................................................32

2 Product Manual
 Contents

5 Motor Sizing..................................................................................... 34
5.1 Load carrying capacity................................................................................................................................ 34
5.1.1 Wheel offset..................................................................................................................................34
5.1.2 Allowed wheel load.....................................................................................................................35
5.1.3 Service life.................................................................................................................................... 35
5.2 Performance...................................................................................................................................................36
5.2.1 Rotating speed and flow rate.................................................................................................. 36
5.2.2 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

Product Manual 3
General Instructions

1 General Instructions

1.1 About the manual

This manual contains the technical instructions for the Black Bruin B200 series
hydraulic motors. Take these instructions into consideration when planning the use
of the product.
All information given in this manual is current and valid according to the information
available at the time of publication. The manufacturer reserves the rights to
implement changes without prior notice.
Please visit www.blackbruin.com for the most recent version of this manual. The
product datasheets and the 3D-models are available from the manufacturer by
request.

1.2 Intended use

Black Bruin B200 series hydraulic motors are designed to be used as hub motors to
produce traction on tractor-driven trailers and working equipment.

1.3 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.

1.4 Product identification

The product identification data can be found on the identification plate attached to
the motor.

1. Model
2. Part number
3. Serial number
4. Displacement
5. Maximum allowed operating pressure

Figure 1. Identification plate of the motor.

Note:
The serial number is also stamped on the motor. All manufacturing data
can be found with the serial number.

1.5 Revision comments

20.10.2017 - This manual is published.

4 Product Manual
 General Instructions

1.6 Declaration of incorporation

Product Manual 5
Safety Instructions

2 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 fluid when disconnecting
the hydraulic connections.

2.1 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.

6 Product Manual
 Motor Description

3 Motor Description

3.1 Working principle

B200 series motors are rotary-housing. This means the motor shaft and the cylinder
block remain in place while the motor is running.

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

Figure 2. The main components of the motor.

The rotation of the motor is achieved by feeding pressurized hydraulic fluid through
the motor shaft 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 stroke.The cam ring pushes the pistons back into the cylinder block preparing
them for the next outward power stroke.

Figure 4. Cylinder block, cam ring and pis-

Figure 3. Flow to the pistons. tons.

Product Manual 7
Motor Description

3.2 Product identification code

Black Bruin product identification code consists of motor model code and processing
ID.
B260-0250-2NOL / GZ - 110000
Motor model code - Processing ID

3.2.1 Motor model code

B200 SERIES MODEL CODE AAAA - BBBB - CCCC / D
Freewheeling hub motors

A: Frame AAAA-BBBB-CCCC/D B240 B250 B260 B270

B240 ●
B250 ●
B200 series frames
B260 ●
B270 ●

B: Displacement AAAA-BBBB-CCCC/D B240 B250 B260 B270

0063 : 630 ccm/rev ●
B240 displacements
0080 : 800 ccm/rev ●
0100 : 1000 ccm/rev ●
B250 displacements 0125 : 1250 ccm/rev ●
0160 : 1600 ccm/rev ●
0200 : 2000 ccm/rev ●
B260 displacements 0250 : 2500 ccm/rev ●
0315 : 3150 ccm/rev ●
0400 : 4000 ccm/rev ●
B270 displacements 0500 : 5000 ccm/rev ●
0630 : 6300 ccm/rev ●

C: Displacement control AAAA-BBBB-CCCC/D B240 B250 B260 B270

1-speed 1N00 : Fixed displacement ● ● ● ●
2N0R : Right side - CW preferred ● ● ● ●
2-speed valve
2N0L : Left side - CCW preferred ● ● ● ●
FW10 : Type 1 - Open freewheel-
● ● ●
ing position
Freewheeling valve
FW20 : Type 2 - Closed free-
● ● ●
wheeling position

D: Accessory AAAA-BBBB-CCCC/D B240 B250 B260 B270

NZ : Fittings for one-time lubri-
● ● ● ●
cation
No drum brake
GZ : Fittings for regular lubrica-
● ● ● ●
tion

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 Motor Description

D: Accessory AAAA-BBBB-CCCC/D B240 B250 B260 B270

MRJ40-0 : Brake size 320x75 ●
MRJ50-0 : Brake size 400x80 ●

Drum brake* MRJ60-R : Brake size 420x220 -

●
Right side
MRJ60-L : Brake size 420x220 -
●
Left side

* = Certified brakes, manufactured by Monroc.

More detailed information and mounting dimensions for each brake device can be found
on the product datasheet.
The drum brake increases the length of the motor assembly and affects the offset value of
the vehicle wheel rim.
Adding lubricant into the seal protector is prevented.

Code example B260 - 0250 - 2N0L / GZ

A - B - C / D
A= The frame of the motor is "B260"
B= The displacement of the motor is 2500 ccm/rev
Internal 2-speed valve for displacement control. The motor is CCW preferred in 2-
C=
speed mode.
D= The seal protector of the motor is fitted for regular lubrication

3.2.2 Processing ID
B200 SERIES PROCESSING ID RMSPDT

RMSPDT Lubrication Definition of factory lubrication

0 = Seal protector is not filled with lubricant. 1)
1 = Seal protector is filled with lubricant.

RMSPDT Painting Definition of the painted surfaces

0 = No painting - Motors are washed and protected from corrosion.
1 = Painting type 1 - Unpainted interfaces: SHAFT, HUB 2)
2 = Painting type 2 - Unpainted interfaces: SHAFT, HUB, HOUSING 2)

RMSPDT Protection Definition of the protection for storage/trans-

portation
0 = Default / Not defined 3)

RMSPDT Packaging Definition of the motor package

0 = Default / Not defined 4)

RMSPDT Documents Definition of the printouts to be attached to the

delivery
0 = Default / Not defined

Product Manual 9
Motor Description

RMSPDT Testing Definition of the testing and reporting

0 = Default / Not defined 5)

Code example 1 1 0 0 0 0
R M S P D T
R= The seal protector of the motor is filled with lubricant.
M= Prime coating. The shaft and hub interfaces of the motor are unpainted.
Pressure openings and threaded holes of the motor are protected according to
S=
general practices of the manufacturer.
P= The motor is packaged according to general practices of the manufacturer.
D= The documentation delivered with the motor is according to general practices of
the manufacturer.
T= The motor is tested according to general practices of the manufacturer.

1)If necessary, the seal protector is not filled with lubricant at the factory.
2) Prime coating: HEMPATHANE HS 55610 or 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.

3.3 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 torque [Nm]
theoretical 3510 4460 5570 6960 8910
with 100 bar 1000 1270 1590 1990 2550
Max. operating power [kW]
at full displacement 35 50
at half displacement 21 30
Max. rotating speed [rpm]
at full displacement 240 185 200 160 125
at half displacement 360 275 300 240 185
at freewheeling 600 500
Min. rotating speed [rpm] 2 2
Max. engaging speed (out of freewheel-
120 93 100 80 63
ing) [rpm]
Brake torque [Nm] 1) 8600 13500
Max. working pressure [bar]
peak pressure 350 350
intermittent 2) 300 300
Max. case pressure [bar]

10 Product Manual
 Motor Description

TECHNICAL DATA B240 B250

average 2 2
intermittent 2) 10 10
Pilot pressure for internal valve [bar]
valve released 0-2 0-2
valve engaged 15-30 3) 15-30 3)
Max. flow rate [l/min]
at full displacement 150 200
at half displacement 113 150
Max. load capacity [t] 4) 4,0 5,4
no brake 59 92
Weight [kg]
with drum brake 96 156

TECHNICAL DATA B260 B270

Displacement [ccm]
at full displacement 2000 2500 3150 4000 5000 6300
at half displacement 1000 1250 1575 2000 2500 3150
Maximum torque [Nm]
theoretical 14300 17900 22600 28600 35800 45100
with 100 bar 3180 3980 5010 6370 7960 10000
Max. operating power [kW]
at full displacement 90 130
at 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-
88 70 55 63 35 40
ing) [rpm]
Brake torque [Nm] 1) 20100 -
Max. working pressure [bar]
peak pressure 450 450
intermittent 2) 400 400
Max. case pressure [bar]
average 2 2
intermittent 2) 10 10
Pilot pressure for internal valve [bar]
valve released 0-2 0-2
valve engaged 15-30 3) 15-30 3)
Max. flow rate [l/min]

Product Manual 11
Motor Description

TECHNICAL DATA B260 B270

at full displacement 350 500
at half displacement 225 325
Max. load capacity [t] 4) 12,5 15,4
no brake 150 285
Weight [kg]
with drum brake 262 -

1) The braking torque is for information only. Braking performance should be

ensured by testing 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.

3.4 Motor interfaces

3.4.1 Main dimensions

Figure 5. Main dimensions of the motor.

MAIN DIMENSIONS B240 B250 B260 B270

Motor
L1 [mm] 262 279 317 377
L2 [mm] 163 177 204 262
D1 [mm] 278 342 408 512

12 Product Manual
 Motor Description

3.4.2 Shaft interface

Figure 6. Dimensions of the shaft interface.

INTERFACE DIMENSIONS B240 B250 B260 B270

Shaft interface
D2 [mm] 140 175 200 260
pattern 6x60° 8x45° 12x30° 16x22,5°
size M16x2,0 M16x2,0 M20x1,5 M20x1,5
strength class
1) 12,9 12,9 12,9 12,9

tightening tor-
330 330 650 650
que 2) [Nm]
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 support and center the motor.

Product Manual 13
Motor Description

The motor is attached to the body of the vehicle or device from the shaft flange. The
hydraulic connections of the motor are located on the plane surface of the shaft
flange.

3.4.3 Hub interface

Figure 7. Dimensions of the hub interface.

INTERFACE DIMENSIONS B240 B250 B260 B270

Hub interface
D5 [mm] 205 275 335 425
pattern 6x60° 8x45° 10x36° 12x30°
size M18x1,5 M20x1,5 M22x1,5 M22x1,5
strength class
1) 10,9 10,9 10,9 10,9

tightening tor-
383 540 728 728
que 2) [Nm]
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 torque.

14 Product Manual
 Motor Description

2)Declared values are for reference only. Always use application specific
tightening torques when given.
The wheel rim or the rotatable device is attached to the motor hub.
Note:
The attachment screws are not included in the motor delivery. Ensure
correct dimensioning and availability of the hub screws.
There are multiple different type of fastening screws for hub interface.
Select the hub screws according to the wheel rim design.

Figure 8. Hub fastening screw variants.

3.4.4 Housing interface

Figure 9. Dimensions of the housing interface.

Product Manual 15
Motor Description

INTERFACE DIMENSIONS B240 B250 B260 B270

Housing interface
D8 [mm] 204 236 274 330
pattern 12x30° 12x30° 18x20° 18x20°
size M10x1,5 M12x1,75 M12x1,75 M16x2,0
strength class1) 10,9 10,9 10,9 10,9
tightening tor-
64 110 110 275
que 2) [Nm]
D9 min. [mm] 184 205 254 302
V2 min. [mm] 1x45° 1x45° 1x45° 1x45°

1) Strength class as in ISO898-1. If using lower strength class, check interface load
capacity and tightening torque.
2) Declared values are for reference only. Always use application 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 when attaching accessories to the housing interface.

Note:
Surface roughness (Ra) of the counterparts must be 12,5μm or better.
More detailed interface dimensions and tolerances are indicated on the
product datasheet.

16 Product Manual
 Motor Description

3.4.5 Drum brake interface

Figure 12. Interface dimensions of the motor with the drum brake (B240, B250).

Figure 13. Interface dimensions of the motor with the drum brake (B260).

INTERFACE DIMENSIONS B240 B250 B260

Drum brake interface
L3 [mm] 277 295 451
D10 [mm] 349 444 460
D11 [mm] 140 175 200
pattern 6x60° 8x45° 12x30°
size M16x2,0 M16x2,0 M20x1,5
strength class
1) 12,9 12,9 12,9

Product Manual 17
Motor Description

INTERFACE DIMENSIONS B240 B250 B260

tightening tor-
330 330 650
que 2) [Nm]
D12 [mm] max. 121 max. 156 min. 235,5
C2 [mm] 4,5 4,5 4,5
V3 min. [mm] 1x45° 1x45° 1x45°
R2 max. [mm] 1 1 1
D13 [mm] 114 150 170

1) Strength class as in ISO898-1. If using lower strength class, check interface load
capacity and tightening torque.
2) Declared values are for reference only. Always use application specific

tightening torques when given.

3.5 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 direction

A→B B→A
1N00, FW10, FW20 CW CCW
2N0R CW CCW
2N0L CCW CW

Preferred operating direction

AAAA - BBBB - 2N0R / D
AAAA - BBBB - 2N0L / D

18 Product Manual
 Motor Description

The preferred operating direction applies to motors with 2-speed valve (see 2-speed
valve : 2N0R / 2N0L on page 21).
The preferred operating direction is the rotating direction of the motor when the flow
direction is from port A to B.
• 2N0R = CW motor (For the right side of a vehicle.)
• 2N0L = CCW motor (For the left side of a vehicle.)

3.6 Mechanical freewheeling

The mechanical freewheeling is a standard feature in the B200 series motors.

Figure 15. A piston with the freewheeling spring.

The motor is equipped with mechanical freewheeling springs, which enable the motor
disengagement. When disengaged the motor may be used without active fluid supply
from the hydraulic system.

USING THE FREEWHEELING

When the motor is depressurized and not rotating, the motor will disengage
automatically. The motor disengagement during motion is done with a freewheeling
valve.
The freewheeling valve may be in-built to the motor (see 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 pistons to retract with aid of mechanical springs.
• DISENGAGING THE MOTOR
Open the freewheeling valve and depressurize the motor with the directional
control valve to disengage the motor.
• ENGAGING THE MOTOR
Close the freewheeling valve and pressurize the motor with the directional control
valve to engage the motor.
The directional control valve and the freewheeling valve are usually activated
simultaneously.
Note:
Another use of the freewheeling is a more extensive speed range for
vehicles having several hydraulic motors. Hydraulic system capacity may

Product Manual 19
Motor Description

be divided between fewer motors, when some of the motors are

disengaged.
Attention:
Any pressure in the working lines (A and B) during the freewheeling
pushes the pistons out of the freewheeling position. This causes clattering
noise when the pistons connect to the cam ring.
Constant clattering of the pistons may cause premature wear or failure of
the motor.

ROTATING SPEED
The rotating speed of the motor should be taken into account when implementing
freewheeling.
• FREEWHEELING SPEED
The freewheeling speed is the highest permissible rotating speed of the motor
during freewheeling.
• ENGAGING SPEED
The engaging speed is the highest permissible rotating speed when engaging the
motor.
The permissible freewheeling and engaging speeds can be found on the technical
data (see Technical data on page 10).

DISENGAGING 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
possible.
• All components and lines, which connect the working lines to the case drain line,
should be sized for highest feasible flow rate.
Attention:
Without freewheeling valve, the delay is considerably longer as the fluid
must seep through the motor. Disengaging the motor during motion
without a freewheeling valve may cause premature wear or failure of the
motor.

3.7 1-speed : 1N00

AAAA - BBBB - 1N00 / D

Displacement control selection 1-speed means the motor has a fixed displacement.
These motors are known as 1-speed motors and are always in full displacement
during operation.

20 Product Manual
 Motor Description

Figure 16. 1-speed motor. Figure 17. Hydraulic circuit, 1-speed motor.

3.8 2-speed valve : 2N0R / 2N0L

AAAA - BBBB - 2N0R / D
AAAA - BBBB - 2N0L / D

The 2-speed valve enables change of displacement during operation. The benefit of
this function is a more extensive speed range with the same hydraulic system
capacity. The motors are also known as 2-speed motors.

Figure 18. 2-speed motor. Figure 19. Hydraulic circuit, 2-speed motor.

The change of displacement works by switching half of the piston to idle. This is done
with the in-built 2-speed valve, which changes the fluid circulation in the motor.

Product Manual 21
Motor Description

USING THE 2-SPEED VALVE

Using the 2-speed valve works in the same manner as gear shifting.
• SHIFTING TO HALF DISPLACEMENT
The motor is switched to half displacement by applying the pilot pressure (see
Pilot pressure on page 32) to the pilot line (Y).
When the motor operates at half displacement, it rotates twice as fast and
generates half of the torque when compared to a motor on full displacement with
the same flow rate and pressure.
The working pressure should be primarily applied into the working line A. The
motor operates at lower efficiency and the operating temperature may rise if
working pressure is applied into the working line B.
• SHIFTING TO FULL DISPLACEMENT
The motor is switched back to full displacement by releasing the pressure in the
pilot line (Y).
When the motor operates at full displacement, it works like the 1-speed motor and
it may be operated normally on both directions.
Attention:
Take the following things into consideration, when changing the speed
range during motion.
• Hydraulic system supply must adjust to the rapid change of 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 in the technical data (see
Technical data on page 10).
Attention:
Continuous use of high working pressure in the working line B at half
displacement may cause premature wear or failure of the motor.

3.9 Freewheeling valve : FW10 / FW20

AAAA - BBBB - FW10 / D
AAAA - BBBB - FW20 / D

The freewheeling valve is used for disengaging the motor during motion (see
Rotating direction on page 18). The freewheeling valve of the motor is an alternative
for the external freewheeling valve (see External freewheeling valve on page 29).
The freewheeling valve connects the working lines to the case drain line inside the
motor. In this way the motor can be disengaged and engaged as smoothly as
possible.

22 Product Manual
 Motor Description

Figure 20. A motor with freewheeling Figure 21. Hydraulic circuit, a motor with
valve. internal freewheeling valve.

FREEWHEELING VALVE TYPE

Please note that the images below also show the crossover position of the valve.
• FW10 = VALVE TYPE 1

The working lines (A and B) of the motor are open (in short circuit), when the
motor is disengaged.
• FW20 = VALVE TYPE 2

The working lines (A and B) of the motor are closed (plugged), when the motor is
disengaged.
Note:
The crossover position of the freewheeling valve momentarily connects
the working lines together inside the motor. This improves disengaging
and engaging of the motor, when compared to the external freewheeling
valve.

USING THE FREEWHEELING VALVE

The freewheeling valve (3) is controlled with the pilot line (F) pressure.
• ENGAGING THE MOTOR
Engage the motor by applying the pilot pressure to the pilot line (F).
When the motor is engaged, it works like the 1-speed motor.
• DISENGAGING THE MOTOR
Disengage the motor by releasing the pressure in the pilot line (F).

Product Manual 23
Motor Description

The orifice (4) in the pilot line (F) dampens the case pressure peaks, if pilot pressure is
higher than recommended (see Pilot pressure on page 32).

3.10 Seal protector : NZ/GZ

The seal protector is a standard feature of the B200 series motors.

1. Relief valve*
2. Nipple (2x180º)
3. Dirt seal
* = not included with B240

Figure 22. The seal protector, the dirt seal, the relief
valve and the nipples.

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. The seal
protector is also known as a grease ring.

3.10.1 Fittings for one-time lubrication

AAAA-BBBB-CCCC / NZ - RMSPDT

The lubricating nipples and relief valve are replaced with plugs to prevent adding
lubricant.

3.10.2 Fittings for regular lubrication

AAAA-BBBB-CCCC / GZ - RMSPDT

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
datasheet.
Note:
The lubrication efficiency can be improved by replacing the relief valve
with a plug (size G1/8"), when the lubricant is starting to drain between
the seal protector and the shaft.

USING THE SEAL PROTECTOR

The seal protector provides the best protection for the motor when lubricant is added
on a regular basis.

24 Product Manual
 Motor Description

• Add lubricant from both nipples during operation. It is recommended to add

lubricant when the motor is warm.
• Lubricate the seal protector as part of the vehicle lubrication routine.
• Observe lubrication adequacy during use and increase or decrease lubrication as
needed.
The lubricant pocket is 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 on page 8).

Figure 23. Possible drainage of lubricant.

Product Manual 25
System Design

4 System Design

4.1 Motor hydraulic circuit

4.1.1 Simple connection

Figure 24. 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.
• 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 Working line pressure on page 32) 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
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 connection and
counter pressure operation.

4.1.2 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.

26 Product Manual
 System Design

PARALLEL CIRCUIT

Figure 25. 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. The system prefers to rotate only the motor, which has the
least resistance.
The flow distribution may be done by sizing the working lines to a certain
flow rate or by throttling them slightly.
Ordinary 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 motors in series circuit.

Two motors in series circuit generate same torque and rotate as fast as one motor
with the same flow rate and pressure.
Attention:
The minimum pressure and a sufficient feed flow must be ensured for all
motors.
The use of series circuit is challenging and therefore is not recommended
for B200 series motors.

Product Manual 27
System Design

4.1.3 Counter pressure operation

Counter pressure operation is needed mainly in series connection (see Motors in
parallel or series circuit on page 26). Counter pressure operation means using the
motor with high back pressure in the return line.
The counter pressure operation affects the torque output of the motor due to
decreased pressure difference over the working lines.
Attention:
Make sure the combined pressure in the working lines does not exceed the
permissible values of the working pressure during counter pressure
operation.
Counter pressure operation is not recommended for B200 series motors,
because high back pressure stresses the motor more than usual
operation.

4.1.4 Hydrostatic braking

Hydrostatic braking means using the output torque of the motor to decelerate the
vehicle. 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 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 hose or
component brakes under high pressure.

4.1.5 Short circuit operation

Short circuit operation means connecting the return flow 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
Mechanical freewheeling on page 19).
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 fluid supply.

Attention:
Make sure the motor does not overheat during short circuit operation.

28 Product Manual
 System Design

4.2 Hydraulic connections

Figure 28. The interface of the motor Figure 29. The hydraulic connections.
hydraulics.

All hydraulic connections of the motor are on the shaft mating surface.
• WORKING LINE PORTS (A and B)
The working lines, aka the feed and return lines of the motor are the high pressure
lines meant for running the motor.
• CASE DRAIN LINE PORT (C)
The case drain line is the return line from the housing cavity.
• PILOT LINE PORT (F or Y)
The pilot line is meant for controlling the 2-speed or freewheeling valve of the
motor (see 2-speed valve : 2N0R / 2N0L on page 21 and Freewheeling valve :
FW10 / FW20 on page 22).

4.3 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 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.

Product Manual 29
System Design

• 2/2 VALVE
When the motor is disengaged using the
2/2 valve (6a), the directional control valve
(1) should have “Y” spool mid position.
Use of the 2/2 valve may be optimized by
switching the freewheeling valve (6a) just
before (max. 0,5 s) the directional control
valve (1). This reduces the pressure in the
return line and minimizes the disengaging
delay.

Figure 30. Freewheeling circuit with a 2/2

valve.

• 4/2 VALVE
Using the 4/2 valve (6b) may be necessary,
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 only the freewheeling
valve.
The 6/2 valve is reliable as the external
freewheeling valve, but it must be sized
for full working line flow rate.

Figure 32. Freewheeling circuit with a 6/2

valve.

30 Product Manual
 System Design

4.4 Hydraulic fluid

4.4.1 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.
• Motor oils in accordance with API-grades SF, SG, SH and SL may also be used.
• Fire resistant hydraulic fluids HFB and HFC or similar may be used under certain
circumstances.

4.4.2 Hydraulic fluid properties

Requirements concerning the hydraulic fluid properties:
• The recommended fluid 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 fluid must reach score 10 on a wear protection test FZG A/8,3/90 in
accordance with ISO 14635-1 (DIN 51354)
• The effect of the additives 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 higher viscosity may
improve the running smoothness.

4.4.3 Hydraulic fluid cleanliness

Hydraulic fluid must fulfill cleanliness level 18/16/13 in accordance with ISO 4406
(NAS 1638 grade 7).
Note:
The purity of the hydraulic fluid has a significant effect on the need for
service and the overall service life of the motor.

4.5 Operating pressures

4.5.1 Case pressure

The case pressure of the motor affects 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.

Product Manual 31
System Design

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 (C) as close to the motor as possible.

4.5.2 Pilot pressure

AAAA - BBBB - 2N0R / D
AAAA - BBBB - 2N0L / D
AAAA - BBBB - FW10 / D
AAAA - BBBB - FW20 / D

The pilot pressure is used to engage the 2-speed or freewheeling valve of the motor.
The recommended pilot pressure is 15 to 30 bar and the maximum allowed pilot
pressure is 350 bar.
Attention:
Over 30 bar pilot pressure causes case pressure peaks. This effect should
be minimized with an orifice in the pilot line. Recommended orifice size is 1
mm.

4.5.3 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 under any
circumstances.
• INTERMITTENT PRESSURE
The value of the intermittent pressure is a permissible value of the working
pressure for a reference period of one minute (1 min). The working pressure may
exceed this value for 10 % of the time during the reference period (for 6 seconds).

MINIMUM PRESSURE
The minimum pressure is a low pressure required in the working lines, which ensures
the motor stays engaged when running. The motor is engaged when the pistons of
the motor stay constantly connected to the cam ring.
The minimum pressure is maintained with back pressure or charge pressure. Type of
the hydraulic system affects the implementation.

• BACK PRESSURE

32 Product Manual
 System Design

In open loop hydraulic system the minimum pressure may be done with back
pressure. The back pressure is usually generated by a suitable check valve with
cracking pressure.
• CHARGE PRESSURE
In closed loop hydraulic system the charge pressure is usually used as the
minimum pressure.
In open loop hydraulic system the charge pressure may be done by a suitable
pressure reducing valve.
The required minimum pressure depends mainly on the flow rate in the working lines.
Recommended values for the minimum pressure are on the following figures:
Working line pressure

[bar] [bar]

Flow rate [l/min]

Figure 33. The minimum pressure at full

displacement (fluid viscosity 35 cSt).

Working line pressure

[bar] [bar]

Flow rate [l/min]

Figure 34. The minimum pressure at half

displacement (fluid viscosity 35 cSt).

Attention:
Too low pressure in the working lines causes the pistons to disconnect
from the cam ring when the motor is running. The effect of this is
clattering noise when the pistons reconnect.
Constant use with too low working line pressure may cause premature
wear or failure of the motor.

Product Manual 33
Motor Sizing

5 Motor Sizing

5.1 Load carrying capacity

5.1.1 Wheel offset

The load carrying capacity of the motor is defined by the offset value of the wheel rim
and the application specific safety factor.
The offset value is the distance from the wheel center line to the wheel interface. The
load charts of the motors are given as a function of offset value. The given load
curves refer to the average wheel load on a single motor.
CL = Center line
M = Motor side
b = ( - ) = Negative offset
b=0 = Zero offset
b = ( + ) = Positive offset

Figure 35. Negative and 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 direction.

Figure 36. Motor orientation to the load direction.

34 Product Manual
 Motor Sizing

5.1.2 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 (flat part).
The load curve is based on peak loads that are about 2x the average load.
MOTOR LOAD CURVE

Load [kN]

Wheel offset,
b[mm]

Figure 37. Motor load carrying capacity

Fmax.

The safety factor of a known wheel 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]

5.1.3 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.

Product Manual 35
Motor Sizing

BEARINGS LOAD CURVE

Load [kN]

Wheel offset,
b[mm]

Figure 38. Bearing load carrying capacity

F10m.

The service life may be estimated with the following equation:

L10h = nominal service life [h]

RPM = rotating speed [rpm]
G = average wheel load [kN]
F10m = bearing load carrying capacity [kN]

5.2 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

or

RPM = rotating speed [rpm]

KMH = vehicle speed [km/h]
or MPS = vehicle speed [m/s]
R = wheel radius [mm]
V = displacement [ccm]
Q = flow rate in working lines [l/min]

FLOW RATE

Note:
Due to motor dynamics, a constant smooth operating speed of under 2
rpm may be difficult to achieve.

36 Product Manual
 Motor Sizing

WORKING SPEED - WHEEL RADIUS

speed [rpm]

speed [km/h]

speed [m/s]

Figure 39. Vehicle speed and motor rotat-

ing speed with different wheel radius.

FREEWHEELING SPEED - WHEEL RADIUS

speed [rpm]

speed [km/h]

speed [m/s]

Figure 40. Vehicle freewheeling speed and

motor rotating speed with different wheel
radius.

5.2.2 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:

Product Manual 37
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]
or RPM = rotating speed [rpm]
V = displacement [ccm]
pw = working pressure [bar]

Note:
Rough estimate of the operating power may be checked by dividing the
available hydraulic power between the motors.

38 Product Manual
 Installation Instructions

6 Installation Instructions

6.1 Mounting the motor

The installation dimensions and tightening torques are given in the product
datasheet.
Check the following things for mounting the motor:
• The counter surfaces must be clean and even.
• Make sure that the strength class (grade) of the fastening screws is sufficient.
• 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 difficult.
• 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 41. Stud bolt variants.

6.2 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.
• After flushing, renew all filters.
Note:
Flushing the hydraulic system should also be performed after every
system modification or repair.

6.3 Air bleeding procedure

Air bleeding procedure is carried out to fill the housing of the motor completely with
hydraulic fluid. Air is removed from the housing with air bleeding screws as follows:
• Locate the air bleeding screws of the housing and turn the motor to a position in
which the screw is at its topmost position.
• Make sure the drain line of the motor is connected.

Product Manual 39
Installation Instructions

• Feed hydraulic fluid into the motor with low pressure throughout the procedure.
• Unscrew the air bleeding screw by half a turn and let air escape from the housing.
• Close the screw when only hydraulic fluid is pouring through it.
• Tighten the screw to a torque of 39 ± 3 Nm.
The location of the air bleed screws is given in the product datasheet.
Note:
If feed pressure is not available, fill the housing manually by pouring
hydraulic fluid in the motor through the topmost opening of the housing.

6.4 Commissioning procedure

Ensure that the following things are in order before starting a new or replaced motor:
• The hydraulic circuit of the motor 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
during the commissioning procedure.
• Start the motor break-in.
Note:
During all installation and service procedures, plug any open ports and
hoses.
When filling the reservoir, add hydraulic fluid through a filter.
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.

40 Product Manual
 Operating Instructions

7 Operating Instructions

7.1 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 first eight hours (8 h) of use.
• The power output should remain under 50 % of the maximum power capacity of
the motor.
• The power output is limited by limiting the working pressure, the speed of rotation
or both.
• The working pressure should be limited so, that pressure peaks which last over
two seconds (2 s) remain under 75 % of the permissible values.
Note:
During the break-in period, the moving parts of the motor wear against
each other so, that the wear of the parts sets to a stable state for the
entire service life of the motor.

7.2 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 flange and housing of the
motor (the shaft seal area).
• Avoid situations in which the motors are completely submerged in water or mud.

7.3 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 difference between the motor and the hydraulic fluid should be
under 60 °C (140 °F).
The operating temperature may be measured from the hydraulic fluid returning from
the motor. Take into account the temperature of hydraulic fluid returning from the
drain line and from the return line (A or B).

7.4 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.

Product Manual 41
Operating Instructions

• Clean the outside of the motor thoroughly, but do not use any solvents.
• Protect the cleaned motor from corrosion.
• If possible, drain all the hydraulic fluid from the motor.
Note:
Dispose of hydraulic fluid should be done appropriately.

42 Product Manual
 Special Instructions

8 Special Instructions

8.1 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 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 instructions are followed, the motor may be stored for
approximately two years. However, as storage conditions do have a
significant effect, these times should only be considered as guide values.

Product Manual 43
 Black Bruin Inc.
+358 20 755 0755
P.O. Box 633, FI-40101 JYVÄSKYLÄ, FINLAND
www.blackbruin.com
[email protected]

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.