boosters - carlisle brake & friction€¦ · compact twin booster 7 boosters speciﬁcations...

E X P E R I E N C E D . G L O B A L . I N N O V A T I V E .

BOOSTERS

HYDRAULIC BOOSTER PRODUCT TECH GUIDE

hydraulic boosters & master cylinders

Complete Brake SystemsCarlisle offers proven brake system designs for a wide range of off-highway vehicles and equipment from the foot pedal to the hydraulic actuator to the brake — including the friction material. We design and build dry disc caliper brakes, drum brakes and mechanical brakes for both service and park applications. When you specify a Carlisle brake system you can count on smooth, quiet and dependable stopping power. Our proven experience and commitment to the global marketplace makes Carlisle the right choice for your new brake, friction or hydraulic actuation design, no matter where you are or what you want to be.

CARLISLE BENEFITS• Complete brake systems — hydraulic controls,

service brakes, park brakes and friction• Proven OE supplier for over 50 years• Manufacturing and engineering support in Asia,

US and Europe

• All designs comply with SAE brake and ISO requirements

• Clean sheet or modified standard designs• Quick turn prototypes• Extensive product testing ensures robost

performance and reliability in service• Maintenance of an inventory of service parts for

all brakes we manufacture

PARTNER TO OEMS AROUND THE WORLDSince our introduction of a caliper disc park brake more than 50 years ago, we’ve been a key partner to most of the off-highway industry’s major OEMs. Our organization is well positioned to provide global customer support, including manufacturing, logistics and service. Carlisle is an experienced supplier of complete brake solutions that OEMs around the world can count on for high performance braking.

2

CBF Hangzhou, China

CBF Pontypool, UKCBF World Headquarters, Solon, OH USA

CBF Bloomington, IN USA

www.carlislecbf.com

3

B O O S T E R S

Boosters Provide Higher Output Pressure to the Brake System Resulting in...

• A significant reduction in pedal effort and pedal travel to achieve the required operating pressure at the brake

• A progressive and controllable braking response offering improved cabin ergonomics and enhanced operator comfort

• A more efficient method of applying the brakes on Off-Highway vehicles

120

110

100

90

80

70

60

50

40

30

20

10

00 200 400 600 800 1000 1200 1400 1600 1800 2000

6.2 : 1 5 : 1 4 : 1

BOOSTED MASTER CYLINDER PERFORMANCEInput Force vs Output Pressure

Knee PointBOOSTER27 mm ∅ Master Cylinder

BOOSTER Knee Point31.75 mm ∅ Master Cylinder

25 bar BoostSupply Pressure

27 mm ØBOOSTER

31.75 mm ØBOOSTER

27 mm ØMaster Cylinder

31.75 mm ØMaster Cylinder

INPUT FORCE (N)

OUTP

UT PR

ESSU

RE TO

BRAK

E (BA

R)PE

DAL T

RAVE

L (mm

)

Boost Ratio27mm Ø BOOSTER31.75mm Ø BOOSTER

Master Cylinder

PEDAL FORCE (N)

EXPORT PRODUCTAND TECHNOLOGYTRENDS

MIDI TWIN BOOSTER

COMPACT TWIN BOOSTER

BOOSTERS require much less input force to achieve Normal Operating Pressure

PEDAL FORCE vs PEDAL TRAVELPrediction based on 6:1 pedal ratio with a fluid volumetric displacement of 16cc / brake.

To achieve the same Pedal Force a Carlisle BOOSTER requires much less pedal travel than a standard master cylinder

Truck legislation imposed on vehicles operating at > 50kph

Increasing brake running clearance reduces brake drag, resulting in improved fuel efficiency and lower operating costs

Braking required on all four wheels

Balanced braking across axles

Drivers demand 'Luxury Car' performance from brake & clutch systems for Off-Highway vehicles

Increasing horsepower, speed and weight requirements in Europe and North America have led to:

250

200

150

100

50

00 100 200 300 400 500 600 700 800

25.4mm Ø M/Cyl 27mm Ø M/Cyl 31.75mm BOOSTER4:1 boost ratio

•

•

•

•

NORMAL OPERATING PRESSURE

WHY USE A BOOSTED MASTER CYLINDER (BOOSTER) INSTEAD OF A STANDARD MASTER CYLINDER?

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BRAKING SYSTEM DIAGRAMS

4

Application Ranges

Brake System DiagramsTYPICAL TRACTOR BRAKING SYSTEM

CARLISLE TWIN BOOSTER APPLICATION CARLISLE TANDEM TWIN BOOSTER APPLICATION

Rear Wheel Brake

Reservoir

Master Cylinders

Oil Tank Rear Wheel Brake

Supply Pressure Oil TankFront WheelBrake

Trailer Brake ,Trailer Brake Lights

Supply Pressure

Rear Wheel Brake

Compact TwinBOOSTER

Tandem TwinBOOSTER

Twin Pedals

Slave Cylinder

2500

10000+

Compact Booster

Midi Booster

Master Cylinders

HORSEPOWER

50－100 HP

80－140 HP

120－300+ HP

Most tractor brake systems use MINERAL oil, but some use VEGETABLE (Glycol) synthetic fluid as used by passenger cars — it is very important that the seals of either are not mixed

Application Ranges



Rear Wheel Brake

Reservoir

Master Cylinders




Supply Pressure

Rear Wheel Brake

Compact TwinBOOSTER

Tandem TwinBOOSTER

Twin Pedals

Slave Cylinder

2500

10000+

Compact Booster

Midi Booster

Master Cylinders

HORSEPOWER

50－100 HP

80－140 HP

120－300+ HP


Application Ranges



Rear Wheel Brake

Reservoir

Master Cylinders




Supply Pressure

Rear Wheel Brake

Compact TwinBOOSTER

Tandem TwinBOOSTER

Twin Pedals

Slave Cylinder

2500

10000+

Compact Booster

Midi Booster

Master Cylinders

HORSEPOWER

50－100 HP

80－140 HP

120－300+ HP


Application Ranges



Rear Wheel Brake

Reservoir

Master Cylinders




Supply Pressure

Rear Wheel Brake

Compact TwinBOOSTER

Tandem TwinBOOSTER

Twin Pedals

Slave Cylinder

2500

10000+

Compact Booster

Midi Booster

Master Cylinders

HORSEPOWER

50－100 HP

80－140 HP

120－300+ HP


Application Ranges



Rear Wheel Brake

Reservoir

Master Cylinders




Supply Pressure

Rear Wheel Brake

Compact TwinBOOSTER

Tandem TwinBOOSTER

Twin Pedals

Slave Cylinder

2500

10000+

Compact Booster

Midi Booster

Master Cylinders

HORSEPOWER

50－100 HP

80－140 HP

120－300+ HP

Most tractor brake systems use MINERAL oil, but some useVEGETABLE (Glycol) synthetic fluid as used by passenger cars — it is very important that the seals of either are not mixed

Application Ranges



Rear Wheel Brake

Reservoir

Master Cylinders




Supply Pressure

Rear Wheel Brake

Compact TwinBOOSTER

Tandem TwinBOOSTER

Twin Pedals

Slave Cylinder

2500

10000+

Compact Booster

Midi Booster

Master Cylinders

HORSEPOWER

50－100 HP

80－140 HP

120－300+ HP


Application Ranges



Rear Wheel Brake

Reservoir

Master Cylinders




Supply Pressure

Rear Wheel Brake

Compact TwinBOOSTER

Tandem TwinBOOSTER

Twin Pedals

Slave Cylinder

2500

10000+

Compact Booster

Midi Booster

Master Cylinders

HORSEPOWER

50－100 HP

80－140 HP

120－300+ HP


Application Ranges



Rear Wheel Brake

Reservoir

Master Cylinders




Supply Pressure

Rear Wheel Brake

Compact TwinBOOSTER

Tandem TwinBOOSTER

Twin Pedals

Slave Cylinder

2500

10000+

Compact Booster

Midi Booster

Master Cylinders

HORSEPOWER

50－100 HP

80－140 HP

120－300+ HP

Most tractor brake systems use MINERAL oil, but some useVEGETABLE (Glycol) synthetic fluid as used by passenger cars — it is very important that the seals of either are not mixed

TYPICAL TRACTOR BRAKING SYSTEMTYPICAL TRACTOR BRAKING SYSTEM

Application Ranges

TYPICAL TRACTOR BRAKING SYSTEM


Rear Wheel Brake

Reservoir

Master Cylinders




Supply Pressure

Rear Wheel Brake

Compact TwinBOOSTER

Tandem TwinBOOSTER

Twin Pedals

Slave Cylinder

2500

10000+

Compact Booster

Midi Booster

Master Cylinders

HORSEPOWER

50－100 HP

80－140 HP

120－300+ HP


Application Ranges



Rear Wheel Brake

Reservoir

Master Cylinders




Supply Pressure

Rear Wheel Brake

Compact TwinBOOSTER

Tandem TwinBOOSTER

Twin Pedals

Slave Cylinder

2500

10000+

Compact Booster

Midi Booster

Master Cylinders

HORSEPOWER

50－100 HP

80－140 HP

120－300+ HP


Application Ranges


CARLISLE TWIN BOOSTER APPLICATION

CARLISLE TANDEM TWIN BOOSTER APPLICATION

Rear Wheel Brake

Reservoir

Master Cylinders




Supply Pressure

Rear Wheel Brake

Compact TwinBOOSTER

Tandem TwinBOOSTER

Twin Pedals

Slave Cylinder

2500

110,000++

Compact Booster

Midi Booster

Master Cylinders

HORSEPOWER

50－100 HP

80－140 HP

120－300+ HP


B O O S T E R S

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APPLICATIONS

Compact Twin BOOStEr

Compact Single BOOStEr

MIDI twin BOOStEr

Tandem Twin BOOStEr

Master Cylinder

tandem Single BOOStEr

5

B O O S T E R S

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6

B O O S T E R S

www.carlislecbf.com

BENEFITS of a Carlisle BOOSTER•

•

•

•

•

•

•

•

• •

•

•

COMPACT TWIN BOOSTER COMPACT SINGLE BOOSTER MIDI TWIN BOOSTER

TANDEM TWIN BOOSTER TANDEM SINGLE BOOSTER MASTER CYLINDER

A wide range of boost ratios and master cylinder diameters can be used to tailor the performance to meet the customer's exact requirementsProvide a progressive and controllable braking response by optimising the “pedal feel” and improving driver comfort and cabin ergonomicsUse of PTFE seal technology provides high wear resistance and extended durability life One million cycles achieved with no deterioration of productSelf-bleed feature allows any air ingress in the master cylinders to be vented to the tank chamber during normal operationNo additional reservoir required: The master cylinder and BOOSTER use a common oil supply thus preventing the cross contamination of fluids or potential ingress of debris Significant reduction in warranty issuesClosed center BOOSTER design minimizes oil usageUses the existing vehicle power hydraulic system to provide servo assist to the master cylinder Patented design for twin or single pedal brake systemsSignificant cost advantage compared to Power Valve productsEase of installation — only four hydraulic connections requiredVarious mounting plate and push rod options available

BOOSTER BENEFITS OVERVIEWComfort & Safety


7

B O O S T E R S

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Specifications

Body LengthOilTested toBOOSTER Ratio

Less than 205 mmMineral Oil1,000,000 Cycles2.65, 4, 5 and 6.2:1

Range of Diameters Supply Pressure Minimum Flow Rate Operation Temperature

25.4 mm to 57 mm15 bar to 40 bar10 L/min-30°C to 100°C

Compact Twin Booster Features• Patented design for mineral oil twin pedal braking systems providing a boosted, progressive pedal feel• Generic design enables performance to be easily matched to most agricultural and industrial vehicle

applications• Self-bleed design keeps BOOSTER purged of any ingressed air• PTFE seal technology ensures extended service life• No reservoir required — uses supply oil for braking systems• Range of metric or imperial ports — to international standards — available• Large variety of pushrod lengths and thread sizes available *• Clevis options available to suit customer requirements

4642

.5

60

203 * 129

Patented closed circuit design with integrated master cylinder BOOSTER and reservoir in a single component

4642

.5

COMPACT SINGLE BOOSTER

8

B O O S T E R S

www.carlislecbf.com

Specifications


Less than 200 mmMineral Oil1,000,000 Cycles2.65, 4, 5 and 6.2:1



Compact Single Booster Features • Patented design for mineral oil single pedal braking systems, providing a boosted, progressive pedal feel• Ideal for clutch applications• Generic design enables performance to be easily matched to most agricultural and industrial vehicle

applications• Self-bleed design keeps BOOSTER purged of any ingressed air• PTFE seal technology ensures extended service life• No reservoir required — uses supply oil for braking or clutch systems• Range of metric or imperial ports — to international standards — available• Large variety of pushrod lengths and thread sizes available *• Clevis options available to suit customer requirements

ø70

5247

192 *

Patented closed circuit design with integrated master cylinder, BOOSTER and reservoir in a single component

MIDI TWIN BOOSTER

9

B O O S T E R S

www.carlislecbf.com

Midi Twin Booster Features• Patented design for mineral oil twin pedal braking systems providing a boosted, progressive pedal feel• Generic design enables performance to be easily matched to most agricultural and industrial applications• Self-bleed design keeps BOOSTER purged of any ingressed air• PTFE seal technology ensures extended service life• No reservoir required — uses supply oil for braking systems• Range of metric or imperial ports — to international standards — available• Large variety of pushrod lengths and thread sizes available *• Clevis options available to suit customer requirements

Specifications

Body LengthOilTested toBOOSTER RatioRange of Diameters

Less than 175 mmMineral Oil1,000,000 Cycles3, 4 and 5:125.4 mm to 30 mm

Supply Pressure

Minimum Flow Rate

Operation Temperature

Vehicle Horsepower*

15 bar to 40 bar

10 L/min

-30°C to 100°C

80 HP to 130 HP

*174

124

60

44.5

35.4

Simplified design reduced weight and smaller size give cost advantages over larger BOOSTERS in the Carlisle BOOSTER family

44.5

35.4

TANDEM TWIN BOOSTER

10

B O O S T E R S

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Specifications


Less than 230 mmMineral Oil1,000,000 Cycles2.65, 4, 5 and 6:1



129

60

4642

.5

229 *

• Patented design for mineral oil twin pedal braking systems providing a boosted, progressive pedal feel• Generic design enables performance to be easily matched to most agricultural and industrial vehicle

applications• Self-bleed design keeps BOOSTER purged of any ingressed air• PTFE seal technology ensures extended service life• No reservoir required — uses supply oil for braking systems• Range of metric or imperial ports — to international standards — available• Large variety of push rod lengths and thread sizes available *• Clevis options available to suit customer requirements

Tandem Twin Booster Features

Pressure Balanced Independent Dual-circuit

Designed for twin pedal vehicles with four independent brakes Trailer brake option

• • •

•

•

TANDEM SINGLE BOOSTER

11

B O O S T E R S

www.carlislecbf.com

Specifications


Less than 220 mmMineral Oil1,000,000 Cycles3, 4 and 5:1

Range of DiametersSupply PressureMinimum Flow RateOperation Temperature

ø70

5646

216.5 *


• Patented design for mineral oil single pedal braking systems providing a boosted, progressive pedal feel• Generic design enables performance to be easily matched to most construction and industrial vehicle

applications• Self-bleed design keeps BOOSTER purged of any ingressed air• PTFE seal technology ensures extended service life• No reservoir required — uses supply oil for braking systems• Range of metric or imperial ports — to international standards — available• Large variety of push rod lengths and thread sizes available *• Clevis options available to suit customer requirements

Tandem Single Booster Features

Designed for single pedal vehicles with split circuit braking

•Independent Dual-circuit

• •

MASTER CYLINDERS

12

B O O S T E R S

www.carlislecbf.com

148.5

123.5

49

60.4

4834

.539

*

*

• Designs for single and twin pedal applications• Twin pedal cylinders feature proven compensation design for dual circuit pressure balance• New self-bleed design features PTFE sealing for improved life and continuous air expulsion• Designed to meet a range of operating pressures and temperatures• Large variety of pushrod lengths and thread sizes *• Range of metric or imperial ports — to international standards — available• Clevis options available to suit customer requirements

Specifications

Mineral and Glycol (DOT3, 4) Range of Diameters 15.8 mm to 31.75 mm Oil

Master Cylinder Features

PRODUCT OVERVIEW

15

B O O S T E R S

www.carlislecbf.com

Integrated

2.6, 4.0,5.0 and 6.2:1

2.6, 4.0,5.0 and 6.2:1

3.2, 4.0and 5.2:1

2.6, 4.0,5.0 and 6.2:1 Not Applicable

27.0, 31.75and 57.0

20.0, 27.0and 76.0

25% to 50%and 100%

27.0, 33.0and 45.0

15.1, 17.1and 21.1

Variable, dependant on Front / Rear requirements

Variable, dependant on Front / Rear requirements

31.75, 35.0and 41.0

25.4, 27.0and 30.0 35

35 35

N/AN/A 100% only

353535.0 and 30.0

202

Mineral Mineral Mineral Mineral Mineral Mineral / Glycol(DOT4)

192 175 230 Various

15.8, 19.0,22.2, 25.4 and27.0

6.85, 9.91,13.05, 17.75 and20.02

Integrated Integrated Integrated Integrated

3, 4 and 5:1

25.4 and 44

17.5 / 17.5

24.3 / 24.3

N/A

220

Requiresseparate system

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✓

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X

✓

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✓

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✓

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✓

X

X

X

X


COMPACT SNGL BOOSTER

MIDI TWIN BOOSTER

TANDEM TWIN BOOSTER

TANDEM SNGLBOOSTER

MASTER CYLINDER

BOOSTER Capability

Boost Ratio Available

Master Cyl Diameter

Master Cyl Stroke

Master Cyl Displ. Available (cc)

Compensation Available (%)

Length mm

Closed Circuit

Reservoir Required

Closed Center

Simple Installation

Steer Turn Facility

Modular Design

Reduced System Complexity

Self-Bleed

Glycol (D0T4) / Mineral Oil

Carlisle...Your Global ResourceToday, more than ever, it is imperative that suppliers are prepared to support their customersaround the world. Carlisle Brake & Friction has established a network of manufacturing anddistribution facilities around the globe that give us a presence in the world’s fastest growingmarkets. This commitment to the global marketplace makes Carlisle the right choice for yournew brake or friction design, no matter where you are or what you want to be.




Today, more than e ver, it is imperat ive that supp liers are prepared to support their customers a round the w orld. Carlisle Brake & Friction has established a network of man ufacturi ng and distribution facilitie s around the globe that give us a pr esence in the world’s fastest growing markets. Thi s commitment to the global marketplace makes Carlisle th e right choi ce for your new brake or frictio n design , no matter where you are or what you want to be.

Carlisle...Your Global ResourceCarlisle...Your Global ResourceToday, more than ever, it is imperative that suppliers are prepared to support their customersaround the world. Carlisle Brake & Friction has established a network of manufacturing anddistribution facilities around the globe that give us a presence in the world’s fastest growingmarkets. This commitment to the global marketplace makes Carlisle the right choice for yournew brake or friction design, no matter where you are or what you want to be.

Carlisle Brake and Friction 6180 Cochran Rd.Solon, OH 44139Phone: 1-855-403-9083 Email: [email protected] us online @ www.CarlisleCBF.com

EXPERIENCED. GLOBAL . INNOVAT IVE .CBF-003OE Rev 6/15

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