N Series Hydraulic Brake Booster (HBB) -1-

HYDRAULIC BRAKE BOOSTER (HBB)

Applicable model
Model year Vehicle model Main market
2003 or later NPR/ NQR All
 N Series Hydraulic Brake Booster (HBB) -2-

HYDRAULIC BRAKE BOOSTER (HBB) SYSTEM FEATURES & COMPONENTS

The hydraulic brake booster, which functions as a brake
14 15
force boosting device that allows the brake to be
6 1 2
operated with less force.
3 The system consists the booster, accumulator, charge
valve, pressure switch, reservoir tank and cooler pipe.
4
7
11 12
13 Booster: It controls the hydraulic pressure to boost the
pedal effort.
Accumulator: It reserves the hydraulic pressure for boost
9
after pump stops.
10 Charge valve: It delivers the hydraulic pressure to the
8 accumulator when the pressure of accumulator is low.
5
Pressure switch: It detects the hydraulic pressure of
accumulator and operates the warning lamp.
1. Booster 6. Brake fluid reservoir tank 11. HBB oil pump
2. Accumulator 7. Master cylinder 12. Power steering oil pump Oil pump: It is driven by engine and delivers the oil to
3. Pressure switch 8. Cooler pipe 13. Steering unit hydraulic brake booster.
4. Charge valve 9. Suction line 14. HBB reservoir tank
5. Brake pedal 10. Return line 15. Power steering reservoir tank Reservoir tank: It reserve the oil to hydraulic brake
booster.
Cooler pipe: It is installed in front of radiator for heat
radiation.
N Series Hydraulic Brake Booster (HBB) -3-
 N Series Hydraulic Brake Booster (HBB) -4-

B
A

D
Section C-C

C C

Section B-B
B
A

Section A-A Section D-D

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HYDRALIC CIRCUIT
Piston Travel limiter
Pivot A
Oil pump Pivot B
Output rod
Input rod
Reservoir
tank

Accumulator

Boost chamber

Lever
Stopper
ON/ OFF valve
Check valve Pivot C

Actuator Sleeve
Dump valve
Pressure switch
Spool valve

Booster assembly

Charge valve assembly

Charge spool valve

 N Series Hydraulic Brake Booster (HBB) -6-

3 HYDRALIC COMPONENTS OPERATION

11
9 2
Normal Condition
1
While brake pedal is not applied, the hydraulic pressure
from the oil pump is returned to the reservoir tank through
the spool valve “a” part. In this state, the spool valve “b”
part is closed and the hydraulic pressure flow from the oil
pump to the boost chamber is blocked.

5 1. Input rod
2. Pivot A
6
3. Piston
7 4. Pivot B
10 8 5. Lever
6. Pivot C
7. Boost chamber
8. Spool valve
9. Output rod
10. Stopper
11. Travel limiter

b a
From oil pump To reservoir tank

8
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3 Boosting Condition (1)

11
9 2
1 When the brake pedal is applied, the input rod (1) moves
forward to the left and presses the pivot B (4) of the lever
(5). The Pivot B (4) locks against the pivot A (2), which
fixed to the piston (3), causing the pivot “C” (6) moves to
the left via the lever (5) and moves the spool valve (8).
Because the movement of the spool valve (8), the “a” part
4 is restricted, causing the pressure to rise, and at the same
time the “b” part opens and high pressure hydraulic
5 1. Input rod
2. Pivot A pressure is directed through the spool valve into the boost
6
3. Piston chamber (7).
7 4. Pivot B
10 8 5. Lever When the hydraulic pressure in the boost chamber (7)
6. Pivot C
7. Boost chamber acts on the piston (3), this pressure is transmitted to
8. Spool valve
9. Output rod output rod (9), moving the piston of the master cylinder.
10. Stopper
11. Travel limiter

b a
From oil pump To reservoir tank

To boost chamber
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3 Boosting Condition (2)

11
9 2
1 When the brake pedal is applied strongly, the input rod (1)
moves further, and the “a” part is blocked while the “b”
part remains open.
In this state, the action of the relief valve built into the oil
pump causes the hydraulic pressure to be circulated
within the pump.
4 When the boosting effort of the hydraulic pressure comes
to an end, thereafter the travel limiter (11) operates, and
5 1. Input rod
2. Pivot A input rod (1) presses directly on piston (3) and the output
6
3. Piston
4. Pivot B
rod (9) via the oil chamber sealed by the travel limiter
7
10 8 5. Lever (11), applying manual force.
6. Pivot C
7. Boost chamber
8. Spool valve
9. Output rod
10. Stopper
11. Travel limiter

b a
From oil pump

To boost chamber
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3 When spool valve (8) hits the stopper (10), the pivot C (6)
11
9 2
which linked with spool valve (8) is held fixed, and then if
1
further input is applied, the bracket (12) separates axially
with respect to the input rod (1) via the pivot B (4) of the
lever (5).
This frees the plunger(13), which had been pressed left by
the bracket (12), oil chamber (15) formed by the end of
the input rod (1) and the hole base of piston is sealed by
4
the steel ball (14), and the input rod (2) and the piston
5 1. Input rod stroke integrally. Thus at the maximum boost, the output
2. Pivot A
6 rod strokes in a relationship of one by one with respect to
3. Piston
7 4. Pivot B
10 8 5. Lever
the input rod (1), the stroke of the output rod (9) which is
6. Pivot C enlarged in the servo region, is maintained without being
7. Boost chamber
8. Spool valve shortened, and the pedal stroke is not increased.
9. Output rod
10. Stopper
11 3 2 11. Travel limiter
Effect by travel limiter
12. Bracket
13. Plunger
5 14. Steel ball Master
cylinder fluid
15. Oil chamber pressure Maximum
1 boost point

15
Boosted
operation

Non boosted
4 operation

14 13 12

Pedal stroke
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3 Released Condition
11
9 2
1
When the brake pedal is released, the input rod (1)
retracts to the right, and the spool valve (8) is returned to
its original position by the return spring.
At the same time, the “a” part is left open and the “b” part
is blocked, and hydraulic pressure flows into the reservoir
tank. The “c” part is opened, and hydraulic pressure in
4
the boost chamber passes though the spool valve (8) and
flows into the reservoir tank, and the piston (3) and the
5 1. Input rod
2. Pivot A output rod (9) are brought back by the return spring.
6
3. Piston
7 4. Pivot B
10 8 5. Lever
6. Pivot C
7. Boost chamber
8. Spool valve
9. Output rod
10. Stopper
11. Travel limiter

c b a
To reservoir tank From oil pump To reservoir tank

From boost chamber

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3 Accumulator Operation
9 2
1
When the oil pump stops and hydraulic pressure is no
longer being supplied to the booster, boosting can be
done at least once by means of the hydraulic pressure
accumulated in the accumulator.
When the brake pedal is applied in this state, the input rod
(1) moves forward, and via the lever (5) locks against the
4
pivot A (2), which is fixed to the piston (3).
This locking motion, through the pivot C (6) causes the
5 1. Input rod
2. Pivot A spool valve (8) to advance and hit the stopper (10), and
6
3. Piston
4. Pivot B
then the sleeve (11) and the actuator (13) slide forward on
7
10 8 5. Lever the spool valve (8), blocking the passage hole (12) of the
6. Pivot C
7. Boost chamber spool valve, then opening dump valve (14).
8. Spool valve
3 2 1 9. Output rod
At this state, the path inside the spool valve (8) is blocked
10. Stopper by the check valve (15), and with the boost chamber (7)
11. Sleeve
12. Passage hole sealed, hydraulic pressure from the accumulator is
13. Actuator received, and the hydraulic pressure force acts on the
14. Dump valve
piston (3).

10 9
4

12

6
11

14 13
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3 Non Boosting Condition

9 2
1
Manual operation results when the oil pump stops, the
flow of hydraulic pressure stops, and the hydraulic
pressure stored in the accumulator is consumed.
When the brake pedal is applied in this state, the input rod
(1) moves forward, and via the lever (5) locks against the
pivot A (2), which is fixed to the piston (3).
4 This locking motion causes the spool valve (8) to
advance, via the pivot C (6), hitting the stopper (10), the
5 1. Input rod
2. Pivot A sleeve (11) and actuator (13) slide further forward on the
6
3. Piston
4. Pivot B
spool valve (8) and strike housing, and pivot C (6) is fixed.
7
10 8 5. Lever When the brake pedal is pressed further, the input rod (1)
6. Pivot C
7. Boost chamber advances, via the pivot B (4) bracket, which is fixed axially
8. Spool valve
3 2 1 9. Output rod
to lever (5), separates from the input rod (1) against the
10. Stopper force of spring, and the end of input rod (1) touches the
11. Sleeve
12. Passage hole hole base of piston (3).
13. Actuator
14. Dump valve In this state, the force of the input rod (1) is transmitted to
the piston (3) and output rod (9), and the manual force
operates on the master cylinder.
10 9
4

12

6
11

14 13
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Charge Valve Operation

1 As the hydraulic pressure in the accumulator falls, the
charge valve operates, and normally the path through
which oil flows from the oil pump to the booster is
4 switched, hydraulic pressure is sent to the accumulator,
2
and pressure storage operation (charge) is done.
To dump Charging is done when the engine is turned on in a state
valve
where the hydraulic pressure in the accumulator is low,
To booster due to accumulator operation after the pump stops or due
spool valve
To
to the pump being stopped for a long time.
reservoir At this state, as shown in the left, the charge spool valve
tank 1. Accumulator
2. Check valve (3) is in position so as to block the oil path to the spool
3. Charge spool valve
4. ON/ OFF valve
valve of the booster, and only the oil path to the
3 5. Seat A accumulator is open.
From oil pump
6. Seat B
Hydraulic pressure from the oil pump, while passing
through this oil path and being stored under pressure in
5
the accumulator, is also led into the rear chamber of the
4 charge spool valve (3) through the seat “A” of the ON/
OFF valve (4), maintaining the position of the charge
3 spool valve (3).

To booster spool valve

To accumulator

From oil pump

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When the pressure in the accumulator (1) becomes high

1 enough and reaches the upper limit set pressure, the seat
“A” of the ON/ OFF valve (4) closes, and at the same time
the seat “B” opens, and hydraulic pressure of the rear
4 chamber of the charge spool valve (3) connects with the
2
oil part to the reservoir.
To dump Thus the pressure in the accumulator (1) maintained at a
valve high level, the pressure in the rear chamber of the charge
To booster spool valve falls, the charge spool valve (3) is pushed
spool valve upward by the hydraulic pressure from the oil pump, the
To
reservoir oil path connects as shown in the left, and the hydraulic
tank 1. Accumulator pressure flows to the spool valve of the booster.
2. Check valve
3. Charge spool valve
4. ON/ OFF valve
3 5. Seat A
From oil pump
6. Seat B

To booster spool valve

To accumulator

From oil pump

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BRAKE BOOSTER LAMP

The brake booster lamp on the IP cluster turns ON when t
he pressure in the actuator is below 5.4 MPa or the ATF l
evel in the reservoir tank is below minimum level.
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Issued by
ISUZU MOTORS LIMITED
SERVICE MARKETING DEPARTMENT
Tokyo, Japan

COPYRIGHT-ISUZU MOTORS LIMITED

SBT-TM-N-HBB-13-01 (Version 1.0)

February 2013

THE RIGHT IS RESERVED TO MAKE CHANGES AT ANY TIME WITHOUT NOTICE