KTR-Group KTR-STOP L light A Series Manual

KTR-STOP®L light-xxx A-xx-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
445123 EN
1 of 21
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note ISO 16016.
Drawn:
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Verified:
2020-11-05 Shg
Replaced by:
KTR-STOP®L light-xxx A-xx-xx
L light-xxx A-xx-xx is a spring-actuated brake in a fixed calliper design serving to
generate a brake force onto a brake disk in order to decelerate a plant’s move-
ment or stop it, respectively, or keep it at standstill.

KTR-STOP®L light-xxx A-xx-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
445123 EN
2 of 21
2
Please observe protection
note ISO 16016.
Drawn:
2020-09-25 Shg/Wie
Replacing:
KTR-N dated 2019-11-21
Verified:
2020-11-05 Shg
Replaced by:
The KTR-STOP®L light-xxx A-xx-xx brake was designed to operate as a service brake and emergency
stop brake. For any other applications please consult with KTR.
1Technical data 3
2Advice 4
2.1 General advice 4
2.2 Safety and advice symbols 4
2.3 General hazard warnings 5
2.4 Intended use 5
3Storage, transport and packaging 5
3.1 Storage 5
3.2 Transport and packaging 5
4Assembly 6
4.1 Components of the brake 6
4.2 Preparation of assembly 8
4.3 Brake pads 9
4.4 Assembly of the brake 9
4.5 Pressure port of a brake 11
4.6 Pressure connection of several brakes 12
4.7 Start-up of the brake 13
4.8 Setting/Re-setting of the brake 14
4.9 Recommendation of liquids to be used 15
4.10 Disassembly of the brake 16
4.11 Spares inventory, customer service addresses 16
4.12 Disposal 17
5Maintenance 17
5.1 Replacement of brake pads 17
5.2 Maintenance of the brake / replacement of single parts 18
5.3 Maintenance and service 20
6Accessories - Sensor 20
6.1 Technical Data „State/wear sensor“ 20
6.2 Assembly / start-up 21
Table of contents

KTR-STOP®L light-xxx A-xx-xx
Operating/Assembly instructions
KTR-N
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Edition:
445123 EN
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Replaced by:
Illustration 1: Dimen-
sional drawing
Table 1: Technical data
L light-xxx A-xx-xx
Weight
[kg]
312
Width of brake pad
[mm]
324
Surface of each brake pad
organic
[mm2]
65,600
Max. wear of each brake pad
[mm]
10
Rated coefficient of friction 1)
[μ =]
0.4
Total brake piston surface - complete brake
[cm2]
279.2
Volume with 1 mm stroke - complete brake
[cm3]
27.92
Max. operating pressure
[bar]
200
Min. thickness of brake disk
[mm]
40
Min. diameter of brake disk
[mm]
1000
Pressure connection
G3/8
Oil bleed
G1/4
Operating temperature
[°C]
-20 to +50
1) The friction coefficient each depends on the application; please consult with KTR.
Table 2: Clamping force, loss of preload force and opening pressure
Brake type
Clamping
force
Fc[kN]
Loss of power
2) [%]
Opening pres-
sure [bar]
Braking torque [Nm] with brake disk Ø [mm]
1000
2000
3000
KTR-STOP®L light-100
100
3.6
95
30800
70800
110800
KTR-STOP®L light-120
120
3.2
105
36900
84900
132900
KTR-STOP®L light-140
140
8.2
130
43100
99100
155100
KTR-STOP®L light-160
160
7.8
170
49200
113200
177200
KTR-STOP®L light-180
180
7.8
175
55400
127400
199400
KTR-STOP®L light-200
200
7.1
185
61600
141600
221600
KTR-STOP®L light-220
220
6.2
200
67700
155700
243700
2) With a stroke of 1 mm (1 mm wear of brake pad)
= 2FF cb
Fb
Fc
= Brake power [kN]
= Clamping force [kN]
1 Technical data

KTR-STOP®L light-xxx A-xx-xx
Operating/Assembly instructions
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Edition:
445123 EN
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Connection dimensions of brake
Illustration 2: Connection dimensions
Please read carefully through these operating/assembly instructions before you start up the brake.
Please pay special attention to the safety instructions!
The operating/assembly instructions are part of your product. Please store them carefully.
The copyright for these operating/assembly instructions remains with KTR.
STOP
Warning of personal injury
This symbol indicates notes which may contribute to pre-
venting bodily injuries or serious bodily injuries that may
result in death.
!
Warning of product damages
This symbol indicates notes which may contribute to pre-
venting material or machine damage.

General advice
This symbol indicates notes which may contribute to pre-
venting adverse results or conditions.
1 Technical data
2 Advice
2.1 General advice
2.2 Safety and advice symbols

KTR-STOP®L light-xxx A-xx-xx
Operating/Assembly instructions
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Edition:
445123 EN
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STOP
With assembly, operation and maintenance of the brake it has to be made sure that the enti-
re drive train is secured against accidental switch-on. You may be seriously hurt by rotating
parts. Please make absolutely sure to read through and observe the following safety indica-
tions.
•All operations on and with the brake have to be performed taking into account "safety first".
•Make sure to switch off the power pack before you perform your work on the brake.
•Secure the power pack against accidental switch-on, e. g. by providing warning signs at the place of switch-on
or removing the fuse for current supply.
•Do not reach into the operating area of the brake as long as it is in operation.
•Secure the brake against accidental contact. Provide for the necessary protection devices.
•Make sure that the overall brake/hydraulic system is depressurized during maintenance operations.
You may only assemble, operate and maintain the brake if you
•have carefully read through the operating/assembly instructions and understood them
•are technically qualified and specifically trained
•are authorized by your company
The brake may only be used in accordance with the technical data (see chapter 1). Unauthorized modifications on
the brake design are not admissible. We will not assume liability for any damage that may arise. In the interest of
further development we reserve the right for technical modifications.
The brake type L light-xxx A-xx-xx described in here corresponds to the technical status at the time of printing
of these operating/assembly instructions.
The brake is delivered in preserved condition and can be stored in a closed, dry place during 12 months.
With favourable storage conditions its properties remain unchanged for up to 12 months.
If the brake is stored over a longer period exceeding 12 months as well as after each transport the corrosion pro-
tection needs to be renewed and the brake has to be activated over the full braking distance in order to prevent
the gaskets from sticking together.
!
The storage rooms must not include any ozone-generating devices like e. g. fluorescent
light sources, mercury-vapour lamps or electrical high-voltage appliances.
Humid storage rooms are not suitable.
Please make sure that condensation is not generated. The best relative air humidity is less
than 65 %.
!
In order to avoid any injuries and any kind of damage please always make use of proper
transport and lifting equipment.
The brake is packed differently each depending on number and kind of transport. Unless otherwise contractually
agreed, packaging will follow the in-house packaging specifications of KTR.
2 Advice
2.3 General hazard warnings
2.4 Intended use
3 Storage, transport and packaging
3.1 Storage
3.2 Transport and packaging

KTR-STOP®L light-xxx A-xx-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
445123 EN
6 of 21
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Please observe protection
note ISO 16016.
Drawn:
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Verified:
2020-11-05 Shg
Replaced by:
The brake is supplied in pre-assembled condition. Before assembly the brake has to be inspected for completen-
ess.
Components/component assemblies of brake –Type L light-xxx A-xx-xx
Compo-
nent/
subas-
sembly
Quantity
Description
Illustration 3: Com-
po-
nents/subassemblie
s of brake
1
2
Housing with compo-
nents
2
2
Brake pad
3
8
Pad retraction set
4
21)
Sensor housing
5
21)
Sensor
1) Optionally available
4 Assembly
4.1 Components of the brake

KTR-STOP®L light-xxx A-xx-xx
Operating/Assembly instructions
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Sheet:
Edition:
445123 EN
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Subassembly 1: Housing with components
Compo-
nent
Quantity
Description
Illustration 4: Housing with single parts
1.1
1
Housing
1.2
1
Scraper
1.3
1
Gasket
1.4
1
Scraper
1.5
1
Gasket
1.6
1
Housing cover
1.7
1
Brake piston
1.8
1
Pressure cylinder
1.9
1
Pipe
1.10
1
Cap screw
DIN EN ISO 4762
1.11
1
Centering sleeve
1.12
1
Set of disk springs
1.13
1
Centering pin
1.14
1
O-ring
1.15
1
Sealing plug
1.16
1
O-ring
1.17
1
O-ring
1.18
1
O-ring
1.19
1
Sealing plug
1.20
1
Screw plug VSTI (acc. to
DIN 908)
1.21
1
1.22
1
Cover
1.23
2
Pad retainer
1.24
10
Hexagon screw
DIN EN ISO 4014
1.25
3
Screw plug VSTI (acc. to
DIN 908)
1.26
2
Screw cap
1.27
1
O-ring
Subassembly 2: Brake pad
Compo-
nent
Quantity
Description
Illustration 5: Brake pad
2.1
1
Plate for brake pad
2.2
1
Pad for brake pad
2.3
4
Pad retainer
2.4
8
Cap screw
DIN EN ISO 4762
4 Assembly
4.1 Components of the brake

KTR-STOP®L light-xxx A-xx-xx
Operating/Assembly instructions
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Edition:
445123 EN
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Subassembly 3: Pad retraction set
Compo-
nent
Quantity
Description
Illustration 6: Pad retraction set
3.1
1
Cap screw
DIN EN ISO 4762
3.2
1
Pipe
3.3
1
Pressure spring
3.4
2
Disk
3.5
1
Sealing plug

To ensure the full braking power, the preparation for assembly needs to be carefully per-
formed.
•The connection plate resp. the stand for the brake as well as the brake disk must be inspected for dimensional
accuracy. For that purpose inspect the connection dimensions, connection surfaces and tolerances as spe-
cified in the drawing (see illustrations 1 and 2).
•Clean and degrease the brake disk and mounting surfaces. Dirt can easily be removed by means of solvents.

The connection between connection plate or stand and brake is defined to be frictionally
engaged. Any residues of oil, dirt and corrosion protection reduce the coefficient of friction.
As a result the operation of the brake and the full braking power are no longer ensured.
!
Observe the manufacturer’s instructions regarding the use of solvents.
4 Assembly
4.1 Components of the brake
4.2 Preparation of assembly

KTR-STOP®L light-xxx A-xx-xx
Operating/Assembly instructions
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Edition:
445123 EN
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
KTR supplies brake pads free from asbestos and lead only.
If requested, we will provide you with the corresponding certificates.
The brake pads are each adapted to the application and delivered accordingly.
They can be distinguished as follows:
•organic material
•powder metal
!
Brake pads are highly sensitive to grease and oil which means that they cannot be cleaned.
Brake pads having such kind of dirt need to be replaced and disposed of.

We would recommend to store the brake pads in their package as long as possible to pro-
tect them from any kind of dirt.
!
Brake pads which have worn off to the wear limit have to be replaced immediately. Make
sure to replace by original parts only.
!
If one half of the brake has to be mounted under pressure (without transport lock) for
reasons of space, please consult with KTR.
STOP
In order to avoid any injuries please always make use of proper lifting equipment.
In the pad retainers there are M12 threads for using lifting devices. The eye bolts should be disassembled after
assembly of the brake and stored in a safe place.
!
In order to avoid any damages on the brake, never twist a rope or any other lifting tool
around damageable components such as sensors, etc.

Before you start with the assembly please check if a sensor has been mounted.
Please remove it before assembly in order to avoid any damages.
!
It is not recommended to use steel plugs for venting.
•Insert the brake pads (subassembly 2) fully into the brake.

If you want to insert brake pads after having assembled the brake, it is necessary to disas-
semble the pad retainers (component 1.23) for that purpose (chapter 5.1).
•Mount the pad retraction sets (subassembly 3) by screwing the screw (component 3.1) with the disk (compo-
nent 3.4), pipe (component 3.2) and pressure spring (component 3.3) into the brake pad.
•Hand-tighten the screw.
•Assemble the sealing plug (component 3.5)
4 Assembly
4.3 Brake pads
4.4 Assembly of the brake

KTR-STOP®L light-xxx A-xx-xx
Operating/Assembly instructions
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Edition:
445123 EN
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
Secure the screw connection (component 3.1) on
the brake pad additionally against working loose,
e. g. conglutinating with Loctite (average
strength).
Illustration 7
Illustration 8
•Insert the first half of the brake (component 1) in the cor-
rect position to the connection plate or stand, respectively
(see illustration 7).
•Insert one of the 6-off connection screws into the brake
until the face of the connection screw is flush with the rear
connection plate respectively stand.

You should preferably insert the connection
screw marked with 1 in illustration 7.
•Insert the second half of the brake in the correct position to
the connection plate or stand, respectively.
•Push the connection screw screwed in before through the
second half of the brake and align it symmetrically.
•Fasten the connection screw at the tightening torques spe-
cified in table 3.
•Repeat this process until the total of 6-off connection
screws have been mounted.

To facilitate the assembly it is possible to fix the position of the brake by one connection
screw only first. Swing in the brake until the balance of the threaded pins can be assembled,
too (see illustration 7).
Table 3: Tightening torques
Screw size
Tightening torque TA[Nm] - 10.9
Untreated and oiled
Tightening torque TA[Nm] - 10.9
Greased with MoS2
M33
2,392
2015
M24
890
754

In order to avoid any contact between the brake disk and the brake resulting from thermal
expansion, the distance of the brake according to illustration 2 needs to be observed.
!
Make sure that the tolerances of the brake disk do not exceed the figures specified in illust-
ration 2.
!
Pressure ports for the housings must be connected symmetrically. It is not allowed to
connect two housings in one brake in series.
4 Assembly
4.4 Assembly of the brake

KTR-STOP®L light-xxx A-xx-xx
Operating/Assembly instructions
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Edition:
445123 EN
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Please observe protection
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Drawn:
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2020-11-05 Shg
Replaced by:
•Connect the pressure oil line to one of the pressure ports of the brake (see illustration 9 and 10). For that pur-
pose remove the screw plug beforehand.
!
The hydraulic lines have to be flushed before connecting to the brake to prevent any partic-
les from penetrating the brake. If the lines are not flushed sufficiently, the gaskets may be
damaged and the operation of the brake is no longer ensured.
•Mount a miniature measuring coupling with a miniature measuring hose to the venting hole (see illustration 9
and 10), for that purpose the screw plug needs to be removed beforehand. Discharge the end of the miniature
measuring hose in a suitable collection container.

The pressure connections on top serve for venting the brake. For a flushing system make
use of one of the pressure connections on top.

Always connect the brake consisting of two halves to a pressure line (see illustration 10),
since the brake disk is loaded with the full braking power on one side in case if one half of
the brake fails.
!
It is not recommended to use steel plugs for venting.
•Connect the leakage oil line to the brake (see illustration 9 and 10). For that purpose remove the sealing plugs
beforehand.

If no leakage oil line is connected, a vacuum may be generated inside the brake which will
damage the gaskets.
!
Never give any pressure on the leakage oil line. Gaskets and scrapers will be destroyed in
this way.

In order to locate a leakage immediately, it is recommended to use a transparent hose and
collection container. Since higher pressures (5 bars at the maximum) are not generated, a
pneumatic hose may be used, too. Inspect the brake for leakages regularly.
!
Severe leakages have to be removed immediately. Oil which has escaped has to be comple-
tely removed, since oil remains may vaporize on hot components and ignite.
Illustration 9: Connections of the leakage oil lines/pressure lines
Illustration 10: Pressure connection of a
brake

Please make sure that the connections and hoses are adapted to the brakes with regard to
pressure, flow rate, temperature and liquid.
Moreover, you have to use flexible hydraulic hoses in order to not limit the motions of the
brake. Any hoses which are located close to mobile components should be secured or
coated accordingly.
4 Assembly
4.5 Pressure port of a brake

KTR-STOP®L light-xxx A-xx-xx
Operating/Assembly instructions
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Edition:
445123 EN
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
If several brakes are assembled we recommend to connect the pressure connection for
each brake individually (in parallel) (see illustration 11).
Please note, if several brakes are connected in a series (see illustration 12), the braking
effect of all following brakes may become effective slightly delayed.
•Connect the pressure oil line to the pressure connec-
tions of the brake (see illustration 10, 11 and 12). For
that purpose remove the screw plugs beforehand.
•Mount a miniature measuring coupling with a minia-
ture measuring hose to the venting hole (see illustra-
tion 10, 11 and 12), for that purpose the screw plug
needs to be removed beforehand. Discharge the end
of the miniature measuring hose in a suitable collec-
tion container.
!
The hydraulic lines have to be flushed
before connecting to the brake to pre-
vent any particles from penetrating the
brake. If the lines are not flushed suffi-
ciently, the gaskets may be damaged
and the operation of the brake is no
longer ensured.
Illustration 11: Pressure connection
of several brakes (in parallel)
Illustration 12: Pressure
connection
of several brakes (in a series)
!
The pressure connection on top serves for venting the brake. For a flushing system make
use of one of the pressure connections on top.

Always connect the brake consisting of two halves to a pressure line (see illustration 11 and
12), since the brake disk is loaded with the full braking power on one side in case if one half
of the brake fails.
!
With the parallel connection of brakes (see illustration 11) each brake needs to be vented
individually.
!
It is not recommended to use steel plugs for venting.
•Connect the leakage oil pipe to the brake (see illustration 10, 11 and 12). For that purpose remove the sealing
plugs beforehand.

If no leakage oil line is connected, a vacuum may be generated inside the brake which will
damage the gaskets.
!
Never give any pressure on the leakage oil line. Gaskets and scrapers will be destroyed in
this way.

In order to locate a leakage immediately, it is recommended to use a transparent hose and
collection container. Since higher pressures (5 bars at the maximum) are not generated, a
pneumatic hose may be used, too. Inspect the brake for leakages regularly.
4 Assembly
4.6 Pressure connection of several brakes

KTR-STOP®L light-xxx A-xx-xx
Operating/Assembly instructions
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Edition:
445123 EN
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Please observe protection
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2020-11-05 Shg
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!
Severe leakages have to be removed immediately. Oil which has escaped has to be comple-
tely removed, since oil remains may vaporize on hot components and ignite.

Please make sure that the connections and hoses are adapted to the brakes with regard to
pressure, flow rate, temperature and liquid.
Moreover, you have to use flexible hydraulic hoses in order to not limit the motions of the
brake. Any hoses which are located close to mobile components should be secured or
coated accordingly.

Before start-up and after each operation on the brake the hydraulic system has to be gene-
rally vented.
Repeat venting the brake several times a year, since any air in the hydraulic system may
affect the operation of the brake and the plant.
!
Please make sure that there is sufficient liquid in the hydraulic system during and after the
venting process.
•Switch on the hydraulic system for a short while to make sure that the brake is flushed with hydraulic oil.
Repeat this process until a stream of clean oil dissipates from the miniature measuring hose.
•Remove the miniature measuring hose.

If the miniature measuring coupling is removed as well, the screw plug needs to be screwed
in the venting hole (see illustrations 11 and 12).
•Dispose of the hydraulic oil of the collection container.
•Put the opening pressure onto the hydraulic system.
•Measure the gap between the brake disk and the brake pad on both sides via a feeler gauge.
•Set the gap to 1 mm by rotating the centering pin (component 1.13) via the external hexagon key width across
flats 36.
!
The hydraulic system must never be operated at a higher pressure than the figures spe-
cified in the type plate of the brake. If any figures or types/sizes are changed, please consult
with KTR.
!
Never keep your fingers between brake disk and brake when applying the brake in order to
prevent serious injuries of your hands. Before every maintenance operation please make
sure that the brake is fully secured against activating.
•Mount the sensor instead of the screw plug.
•The brake pads have to be ground in on the surface of the brake disk to achieve the nominal coefficient of
friction.
4 Assembly
4.6 Pressure connection of several brakes
4.7 Start-up of the brake

KTR-STOP®L light-xxx A-xx-xx
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Edition:
445123 EN
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2020-11-05 Shg
Replaced by:

The brake needs to be set with the initial assembly or after having replaced the brake pads
or single parts, respectively. Only in this way it is ensured that the brake has the clamping
force specified.

In case of wear of the brake pads the brake needs to be regularly reset.
•Remove the sensor.
•Put the opening pressure onto the hydraulic system.

Please note chapter 4.7 Start-up of brake.
•Remove the screw plug (component 1.22) and the safety plate
(component 1.21) on both sides.
Illustration 13: Setting/re-setting of the brake

Tilting of the safety plate can be untightened by
rotating the centering pin (component 1.13) by
2°- 3°.
•Measure the gap between the brake disk and the brake pad on
both sides via a feeler gauge.
•Set the gap to 1 mm by rotating the centering pin (component
1.13) via the external hexagon key width across flats 36.
•Applying for resetting of the brake only (wear of brake
pad):
With a wear of the brake pads (1 mm wear for each brake pad)
of 2 mm the centering pin needs to be screwed in by 1/3 revo-
lution.
•Screw in the safety plate (component 1.21) onto the centering
pin (component 1.13) on both sides.
•Screw in the screw plug (component 1.22) into the housing
cover (component 1.6) against a stop.

The gap between brake disk and brake pad needs to be 1 mm on both sides to ensure the
brake power.
•Assemble the sensor.
4 Assembly
4.8 Setting/Re-setting of the brake

KTR-STOP®L light-xxx A-xx-xx
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Edition:
445123 EN
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Please observe protection
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Drawn:
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Verified:
2020-11-05 Shg
Replaced by:
!
You may only use mineral hydraulic liquids meeting the specifications of DIN 51524. KTR
recommends those liquids corresponding to DIN 51524-3.
KTR recommends the following liquids (other manufacturers may be selected):
Manufacturer
Standard
Special
Mineral oil
-20 °C to +40 °C
(-4 °F to +104 °F)
10 °C to 60 °C
(50 °F to 140 °F)
-30 °C to +20 °C
(-22 °F to +68 °F)
30 °C to 70 °C
(86 °F to 158 °F)
Castrol
Hyspin HVI 32
Hyspin HVI 46
-
Hyspin HVI 68
Shell
Tellus S2 VX32
Tellus S2 VX46
Tellus S4 VX32
Tellus S2 VX68
Mobil
DTE 10 Excel 32
DTE 10 Excel 46
-
DTE 10 Excel 68

The permissible operating temperatures of brake components from -20 °C to +60 °C (-4 °F to
+140 °F) have to be observed. For different operating temperatures please consult with KTR.
Viscosity
We would recommend a viscosity range from 20 to 220 mm2/s (cSt) of the hydraulic liquid with operating tempera-
ture. The viscosity during starting should not exceed 500 mm2/s and the viscosity during operation should not fall
below 12 mm2/s.
Filtration
When filling and re-filling the hydraulic system and replacing the hydraulic liquid, the oil needs to be filtered. For
that purpose use an offline filter or a respective fill unit. In addition we would recommend to use an inline filter.

The service life of the brake system is extended depending on the degree of purity of the oil.
As a standard the KTR basic power packs are equipped with a 10 µm inline filter.
In order to ensure the reliability of the system, only those oils originating from the following purity class are permit-
ted:
•ISO 4406, class 18/16/13
Maintenance operations on the hydraulic system
In order to ensure smooth operation of the overall system, maintenance operations on the hydraulic system (in-
spection of level and degree of dirt, replacing the hydraulic liquid or filter elements, etc.) have to be performed as
per the manufacturer's operating instructions.
The system has to be flushed or vented after each replacement of the hydraulic liquid.
!
Adverse reactions may be generated by mixing different liquids or liquids of various manu-
facturers.

Please contact the manufacturer of mineral oils if you intend to replace the hydraulic liquid.
4 Assembly
4.9 Recommendation of liquids to be used

KTR-STOP®L light-xxx A-xx-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
445123 EN
16 of 21
2
Please observe protection
note ISO 16016.
Drawn:
2020-09-25 Shg/Wie
Replacing:
KTR-N dated 2019-11-21
Verified:
2020-11-05 Shg
Replaced by:
STOP
In order to avoid any personal injuries, protect the brake by means of the assembly lock.
•Put the opening pressure (see table 2) onto the hydraulic system. Make sure the brake is fully opened or the
brake piston (component 1.7) fully bears on the stop of the housing cover (component 1.6).
•Remove the sensor (component 4 and 5).
•Remove the screw plug (component 1.22) and the safety plate (component 1.21) on both sides.

Rotating the centering pin by 2° to 3° allows to untighten the safety plate (component 1.21)
more easily.
•Rotate the centering pin (component 1.13) counterclockwise by means of the external hexagon key width
across flats 36. Make sure the centering pin is fully untightened against a stop.
•Release the pressure fully from the hydraulic system.
!
Make sure that the entire brake system is depressurized.
STOP
Parts released or falling down may cause injury to persons or damage on the machine.
Secure the components before disassembly.
•Disconnect the leakage oil and pressure oil line from the brake.
•Drain the hydraulic oil completely from the brake.
•Dispose of the hydraulic oil as per chapter 4.12.
•Screw the screw plugs (component 1.25 and 1.26) in all pressure connections.
•Disassemble all fastening hexagon nuts and washers.
•Take out both halves of the brake (component 1).
A basic requirement to ensure the readiness for use of the brake is a stock of the most important spare parts on
site.
Contact addresses of the KTR partners for spare parts and orders can be obtained from the KTR homepage at
www.ktr.com.

KTR does not assume any liability or warranty for the use of spare parts and accessories
which are not provided by KTR and for the damages which may incur as a result.
4 Assembly
4.10 Disassembly of the brake
4.11 Spares inventory, customer service addresses

KTR-STOP®L light-xxx A-xx-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
445123 EN
17 of 21
2
Please observe protection
note ISO 16016.
Drawn:
2020-09-25 Shg/Wie
Replacing:
KTR-N dated 2019-11-21
Verified:
2020-11-05 Shg
Replaced by:
In respect of environmental protection we would ask you to dispose of the products on termination of their service
life in accordance with the legal regulations and standards that apply, respectively.
•Metal or brake pads, respectively
Brake pads and any other metal parts have to be cleaned and disposed of by scrap metal.
•Gaskets
Gaskets can be disposed of by residual waste.
•Sensors
Electrical components have to be treated as electrical waste.
•Hydraulic oil
Hydraulic oils have to be collected in suitable tanks and disposed of by a waste disposal company.

Brake pads having a balance of pad height of less
than 2 mm have to be replaced by return.
Illustration 14: Replacement of brake pads

Replace the brake pads in both halves of the brake
simultaneously.
STOP
Parts released or falling down may cause injury to
persons or damage on the machine. Secure the
components before disassembly.
!
Never keep your fingers between brake disk and
brake when applying the brake in order to prevent
serious injuries of your hands. Before every main-
tenance operation please make sure that the brake
is fully secured against activating.
•Disassemble the pad retainers (component 1.23) on one side mutually.
•Remove the two pad retainers (component 2.3) on one side mutually.
•Replace the brake pads that have worn off by pushing only the pad out of respectively into the plate.
•Hand-tighten the pad retainers (component 1.23) mutually by each 5 hexagon screws (component 1.24) first.
Tighten the screws at the tightening torque TA= 302 Nm.
•Hand-tighten the pad retainers (component 2.3) on both sides by each 2-off cap screws (component 2.4) first.
Tighten the screws at the tightening torque TA= 36 Nm.
•Repeat chapter 2.4 Setting/re-setting of the brake
•Make sure that the brake disk can rotate freely while not touching the brake pads or the housing.

Please note chapter 2 Assembly of the brake.
•Before you reactivate the brake, observe chapter 2.3 Start-up of the brake.
4 Assembly
4.12 Disposal
5 Maintenance
5.1 Replacement of brake pads

KTR-STOP®L light-xxx A-xx-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
445123 EN
18 of 21
2
Please observe protection
note ISO 16016.
Drawn:
2020-09-25 Shg/Wie
Replacing:
KTR-N dated 2019-11-21
Verified:
2020-11-05 Shg
Replaced by:

To ensure the full braking power, both disassembly
and assembly have to be performed at the highest
level of purity.
Illustration 15: KTR-STOP®L light-xxx A-xx-xx
(Half of brake)
•Disassemble the brake, please observe chapter 4.10 Disassembly
of the brake.
•Remove the pad retraction sets (component 3).
•Take out the brake pad (component 2).
•Remove the O-ring (component 1.14).
•Connect the brake to the hydraulic system or a hydraulic hand
pump.
•Rotate the centering pin (component 1.13) counterclockwise by
means of the external hexagon key width across flats 36. Make su-
re the centering pin is fully untightened against a stop.

Make sure that the entire brake system is depressu-
rized.
•Screw the housing cover (component 1.6) fully out of the housing
(component 1.1).
•Remove the housing cover (component 1.6) and the set of disk
springs (component 1.12).

Make use of a tool to ensure the same arrangement
of disk springs, washer and adjustment washer(s)
with re-assembly of the brake.
•Press the brake piston (component 1.7) with the centering sleeve (component 1.11), the centering pin (com-
ponent 1.13) and the pressure cylinder (component 1.8) carefully out of the housing (component 1.1) by me-
ans of some hydraulic pressure.
!
Inspect the components/subassemblies 1 and 14 for any kind of damages; it may be neces-
sary to replace the components. Afterwards remove dirt, grease and corrosion from the
components.
•Remove the gaskets (component 1.3 and 1.5) and the scraper (component 1.2 and 1.4).

When removing the gaskets and scrapers make sure that the keyways in the housing are
not damaged.
•The components have to be cleaned from dirt, grease and corrosion protection. The components can easily be
cleaned by means of solvents. Afterwards dry the components.
!
Observe the manufacturer’s instructions regarding the use of solvents.
•Insert new gaskets (component 1.3 and 1.5) and scrapers (component 1.2 and 1.4) into the housing (compo-
nent 1.1). For that purpose the components may be heart-shaped (see illustration 16).
!
The gasket and scraper have to be installed in the right direction (see illustration 17).
5 Maintenance
5.2 Maintenance of the brake / replacement of single parts

KTR-STOP®L light-xxx A-xx-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
445123 EN
19 of 21
2
Please observe protection
note ISO 16016.
Drawn:
2020-09-25 Shg/Wie
Replacing:
KTR-N dated 2019-11-21
Verified:
2020-11-05 Shg
Replaced by:

With reassembly of the brake piston basically new gaskets and scrapers have to be used,
since their operativeness is no longer ensured due to wear and damages.
•Grease the gaskets and scrapers with hydraulic oil (see illustration 17).
!
Oils and greases containing molybdenum disulphite or zinc sulphite additives must not be
used.
Illustration 16: Assembly of gasket and scraper
Illustration 17
!
Inspect the surfaces of the brake piston (component 1.7) and the hole of the sleeve in the
housing (component 1.1) to make sure that they are neither scratched nor damaged, since
the surfaces are either ground or polished. Such kind of damages may cause earlier wear
on the gaskets and scrapers and generate leakages.
•Insert the brake piston (component 1.7) with the centering sleeve (component 1.11), the centering pin (com-
ponent 1.13) and the pressure cylinder (component 1.8) into the housing and press it against a stop.

A mounting device may be necessary; for that purpose please consult with KTR.
•Push the set of disk springs (component 1.12) on the centering sleeve (component 1.11) up to the brake pis-
ton (component 1.9).

Lubricate the disk springs properly with Molykote MoS2.
Make sure that the set of disk springs is remounted in the same arrangement as it was
supplied.
If a new set of disk springs is used, the condition of supply needs to be observed in detail.
•Insert a new O-ring (component 1.14) between the housing cover (component 1.13) and the housing (compo-
nent 1.1).
•Screw the screw plug (component 1.25) into all pressure connections.
•Insert the brake pads (component 2) fully into the brake (subassembly 1).

If you want to insert brake pads after having assembled the brake, it is necessary to disas-
semble the pad retainers (component 1.25) for that purpose (chapter 5.1).
•Push the washers (component 3.4) on the cap screw (component 3.1).
•Set the pipe (component 3.2) and the pressure spring (component 3.3) on the pin.
•Screw the pad retraction sets (component 3) into the housing (component 1.1) against a stop.
5 Maintenance
5.2 Maintenance of the brake / replacement of single parts

KTR-STOP®L light-xxx A-xx-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
445123 EN
20 of 21
2
Please observe protection
note ISO 16016.
Drawn:
2020-09-25 Shg/Wie
Replacing:
KTR-N dated 2019-11-21
Verified:
2020-11-05 Shg
Replaced by:
•Seal the bores via the sealing plugs (component 3.5).

Secure the screw connection (subassembly 3) on the brake pad additionally against work-
ing loose, e. g. conglutinating with Loctite (average strength).
•Repeat chapter 4.8 Setting/re-setting of the brake

Please note chapter 4.4 Assembly of brake.
•Before you reactivate the brake, please observe chapter 4.7 Start-up of the brakes.
KTR-STOP®L light-xxx A-xx-xx is a low-maintenance brake. We recommend to perform a visual inspection and
an operational testing on the brake at least once a year.
Here you should put special emphasis on leakages, corrosion, wear of brake pads and the condition of the screw
connections.

If you realize any irregularities, please perform repairs accordingly.
Operation of sensor
There are two micro switches in the housing of the
sensor. The spacer pin activates the switches in two
different positions.
Illustration 18:
State/wear
sensor
Table 4: Switching status of status (switch S1) and wear switch (switch S2) depending on the activating
status of the brake.
Status of brake
Condition of
brake pad
Switch
S1
Switch
S2
Illustration 19: Switch position
(status signal
on/off) 1)
(wear signal) 1)
1 - 4 2)
2 - 3 2)
2 - 5 2)
Sensor not moun-
ted
-
0
0
1
Brake not acti-
vated (unlocked)
-
1
1
0
Brake activated
(locked)
No wear
0
1
0
Resetting neces-
sary
0
0
1
1) Status of brake
on = brake open
off = brake locked
2) Switch position
0 = open
1 = locked
5 Maintenance
5.2 Maintenance of the brake / replacement of single parts
5.3 Maintenance and service
6 Accessories - Sensor
6.1 Technical Data „State/wear sensor“