Boosters

CBF Bloomington, IN USA CBF Pontypool, UK

CBF World Headquarters,

CBF Hangzhou, China
Solon, OH USA

Complete Brake Systems

Carlisle 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. In addition, now many of our brakes are
manufactured in our Hangzhou, China plant... ensuring you get the most cost effective, highest quality brake system
in the world.

Carlisle Benefits Partner to oeMs around the World

• Complete brake systems — hydraulic controls, Since our introduction of a caliper disc park brake more than 50 years
service brakes, park brakes and friction ago, we’ve been a key partner to most of the off-highway industry’s major
• Proven OE supplier for over 50 years OEMs. Our organization is well positioned to provide global customer
• Manufacturing and engineering support in Asia, support, including manufacturing, logistics and service. Carlisle is an
US and Europe experienced supplier of complete brake solutions that OEMs around the
• All designs comply with SAE brake world can count on for high performance braking.
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

2
Why Use a Boosted Master Cylinder (Booster) Instead of a Standard
Master Cylinder?
BOOSTERS provide a 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.

Boosters require much less input force to achieve Normal operating Pressure

Export Product and

Boosted Master Cylinder PerforManCe
Input Force v Output Pressure

Technology Trends
120
27mm Ø
BOOster Knee Point
booster
110 27mm Ø Master Cylinder

100
outPut Pressure to Brake (Bar)

90
BOOster Knee Point 31.75mm Ø
80 31.75mm Ø Master Cylinder booster

70

60
25 bar Boost
50 Supply Pressure Normal Operating Pressure
MIDI TWIN Booster 27mm Ø
40
Master Cylinder
30 31.75mm Ø
Master Cylinder
20

10

0
0 200 400 600 800 1000 1200 1400 1600 1800 2000
inPut forCe (n)

COMPACT TWIN Booster Boost Ratio 6.2 : 1 5:1 4:1 Master Cylinder
27mm Ø Booster
31.75mm Ø Booster
Drivers demand ‘Luxury Car’
performance from brake &
clutch systems for
to achieve the same Pedal Force a Carlisle Booster requires much
off-Highway vehicles
less pedal travel than a standard master cylinder.
Increasing horsepower, speed and
weight requirements in europe and Pedal forCe vs Pedal traVel
North America have led to; Prediction based on 6:1 pedal ratio with a fluid volumetric displacement of 16cc / brake.
250
truck legislation
imposed on vehicles
200
operating at > 50kph
Pedal traVel (mm)

Increasing brake running

150
clearance reduces brake
drag, resulting in
improved fuel efficiency 100

and lower operating costs

Braking required on 50

all four wheels

Balanced braking 0
across axles 0 100 200 300 400 500 600 700 800
Pedal forCe (n)

25.4mm Ø M/Cyl 27mm Ø M/Cyl 31.75mm booster

4:1 boost ratio

www.CarlisleCBF.com 3
 BOOSTERS

Braking System Diagrams

TYPICAL TRACTOR BRAKING SYSTEM
reservoir

rear Wheel Brake

slave cylinder

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

twin Pedals Master Cylinders

carlisle Twin Booster Application carlisle Tandem Twin Booster Application

Compact twin
OOSTER

trailer Brake
trailer Brake lights tandem twin
OOSTER

rear Wheel Brake

oil tank rear Wheel Brake
front Wheel
supply Pressure supply Pressure oil tank Brake

ES
10000+
Gross VeHICLe WeIGHt (kG)

COMPACt BOOster
120—300+ HP

80—140 HP
MIdI BOOster

50—100 HP
MAster CylInders
2500
HorsePoWer

4
 BOOSTERS

Applications

Compact Twin Booster

Compact Single Booster

MIDI Twin Booster

Trailer Brake

Tandem Twin Booster

Tandem Single BOOSTER

Master Cylinder

www.CarlisleCBF.com 5
 BOOSTERS

Benefits of a Carlisle BOOSTER

Comfort & Safety
A wide range of boost ratios and master cylinder diameters can be used to tailor
the performance to meet the customer's exact requirements.
Provides a progressive and controllable braking response by optimising the “pedal
feel” and improving driver comfort and cabin ergonomics.
Use of PTFE seal technology provides high wear resistance and extended durability
life. One million cycles achieved with no deterioration of product.
Self-bleed feature allows any air ingress in the master cylinders to be vented to the
tank chamber during normal operation.
No 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 issues.
Closed centre booster design minimizes oil usage.
Uses the existing vehicle power hydraulic system to provide servo assist to the
master cylinder.
Patented design for twin or single pedal brake systems.
Significant cost advantage compared to Power Valve products.
Ease of installation — only four hydraulic connections required.
Various mounting plate and push rod options available.

Compact Compact MIDI

Twin Booster Single Booster Twin Booster

Tandem Twin Booster Tandem single Booster Master Cylinder

6
 BOOSTERS

COMPACT TWIN BOOSTER

Patented closed circuit design with integrated master cylinder
BOOster and reservoir in a single component.
» 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.

203 * 129

46
42.5
60

Specifications
Body Length Less than 205mm Range of Diameters 25.4 to 57mm
Oil Mineral Oil Supply Pressure 15 bar to 40 bar
Tested to 1,000,000 Cycles Minimum Flow Rate 10L / min
Booster Ratio 2.65, 4, 5 and 6.2:1 Operation Temperature -30°C to 100°C

www.CarlisleCBF.com 7
 BOOSTERS

COMPACT SINGLE
BOOSTER
Patented closed circuit design with integrated master cylinder,
BOOster and reservoir in a single component.
» 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.

192 * ø70

52
47

Specifications
Body Length Less than 200mm Range of Diameters 25.4 to 41mm
Oil Mineral Oil Supply Pressure 15 bar to 40 bar
Tested to 1,000,000 Cycles Minimum Flow Rate 10L / min
Booster Ratio 2.65, 4, 5 and 6.2:1 Operation Temperature -30°C to 100°C

8
 BOOSTERS

MIDI TWIN BOOSTER

simplified design reduced weight and smaller size give
cost advantages over larger BOOsters in the Carlisle
BOOster family.
» 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.

174 * 124

60 44.5
35.4

Specifications
Body Length Less than 175mm Supply Pressure 15 bar to 40 bar
Oil Mineral Oil Minimum Flow Rate 10L / min
Tested to 1,000,000 Cycles Operation Temperature -30°C to 100°C
Booster Ratio 3, 4 and 5:1 Vehicle Horsepower* 80 HP to 130 HP
Range of Diameters 25.4 to 30mm *Additional Feature

www.CarlisleCBF.com 9
 BOOSTERS

TANDEM TWIN BOOSTER

Braking CaPaBilities:
• Pressure Balanced • Independent • dual-circuit
• designed for twin pedal vehicles with four independent brakes
with trailer brake option.
»» 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.

229 * 129

46
42.5

60

Specifications
Body Length Less than 230mm Range of Diameters 25.4 to 35mm
Oil Mineral Oil Supply Pressure 15 bar to 40 bar
Tested to 1,000,000 Cycles Minimum Flow Rate 10L / min
Booster Ratio 2.65, 4, 5, and 6:1 Operation Temperature -30°C to 100°C

10
 BOOSTERS

TANDEM SINGLE BOOSTER

Braking CaPaBilities:
• Independent • dual-circuit
• designed for single pedal vehicles with split circuit braking.
»» 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.

216.5 * ø70

56
46

Specifications
Body Length Less than 220mm Range of Diameters 25.4 to 44mm
Oil Mineral Oil Supply Pressure 15 bar to 40 bar
Tested to 1,000,000 Cycles Minimum Flow Rate 10L / min
Booster Ratio 3, 4 and 5:1 Operation Temperature -30°C to 100°C

www.CarlisleCBF.com 11
 BOOSTERS

MASTER CYLINDER
» 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.

148.5 * 49

60.4
39
123.5 *
48
34.5

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

12
 BOOSTERS

PRODUCT OVERVIEW

CoMPaCt twin CoMPaCt Midi twin tandeM twin tandeM single Master
Booster single Booster Booster Booster Booster Cylinder
Requires
Booster Capability Integrated Integrated Integrated Integrated Integrated
separate system

2.6, 4.0, 2.6, 4.0, 3.2, 4.0 2.6, 4.0,

Boost Ratio Available 5.0 and 6.2:1 5.0 and 6.2:1 and 5.2:1 5.0 and 6.2:1
3, 4, 5:1 Not Applicable

15.8, 19.0,
27.0, 31.75 31.75, 35.0 25.4, 27.0
Master Cyl Diameter and 57.0 and 41.0 and 30.0
35 25.4, 44 22.2, 25.4,
27.0

Master Cyl Stroke 35.0 and 30.0 35 32 35 17.5 / 17.5 35

Master Cyl Variable,

6.85, 9.91,
20.0, 27.0 27.0, 33.0 15.1, 17.1 dependant on
Displacement and 76.0 and 45.0 and 21.1 Front / Rear
24.3 / 24.3 13.05, 17.75,
Available (cc) 20.02
requirements

Variable,
Compensation 25% to 50% dependant on
N/A 100% only N/A N/A
Available (%) and 100% Front / Rear
requirements

Length mm 202 192 175 230 220 Various

Closed Circuit

Reservoir Required

Closed Center

Simple Installation

Steer Turn Facility

Modular Design

Reduced System
Complexity

Self-Bleed

Glycol (DOT4) / Mineral / Glycol

Mineral Mineral Mineral Mineral Mineral
Mineral Oil (DOT4)

www.CarlisleCBF.com 13
 Carlisle...Your Global Resource
Today, more than ever, it is imperative that suppliers are prepared to support their
customers around the world. Carlisle Brake & Friction has established a network of
manufacturing and distribution facilities around the globe that give us a presence in
the world’s fastest growing markets. This commitment to the global marketplace
makes Carlisle the right choice for your new brake or friction design, no matter
where you are or what you want to be.

Carlisle Brake and Friction

6180 Cochran Rd.
Solon, OH 44139
Phone: 1-855-403-9083
Email: sales@carlislecbf.com Visit us online @ www.CarlisleCBF.com

EXPERIENCED. GLOBAL. INNOVAT IVE.