KTR-Group KTR-STOP M-A-F B Series Manual

KTR-STOP®M-A-F B-xx
Operating/Assembly instructions
KTR-N
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Edition:
445145 EN
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KTR-STOP®M-A-F B-xx
M-A-F B-xx is a brake actuated hydraulically in a floating caliper design serving
to generate a brake force on a brake disk in order to decelerate a machine's mo-
vement or stop it, respectively, or keep it at standstill.

KTR-STOP®M-A-F B-xx
Operating/Assembly instructions
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445145 EN
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The KTR brake system was designed to operate as a service brake/emergency stop brake on rotating
brake disks. For any other applications please consult with KTR.
1Technical data 3
2Advice 5
2.1 General advice 5
2.2 Safety and advice symbols 5
2.3 General hazard warnings 6
2.4 Intended use 6
3Storage, transport and packaging 6
3.1 Storage 6
3.2 Transport and packaging 6
4Assembly 7
4.1 Components of the brake 7
4.2 Preparation of assembly 9
4.3 Brake pads 10
4.4 Assembly of the brake 10
4.5 Setting/resetting of the centering system 12
4.6 Pressure connection of a brake 13
4.7 Pressure connection of several brakes 14
4.8 Start-up of the brake 15
4.9 Recommendation of fluids to be used 15
4.10 Disassembly of the brake 16
4.11 Spares inventory, customer service addresses 17
4.12 Disposal 17
5Maintenance 17
5.1 Replacement of brake pads 17
5.2 Maintenance of the brake / replacement of single parts 19
5.3 Maintenance and service 21
6Accessories - Sensor 22
6.1 Technical Data „State/wear sensor“ 22
6.2 Assembly / start-up 23
Table of contents

KTR-STOP®M-A-F B-xx
Operating/Assembly instructions
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Illustration
1: Dimen-
sional dra-
wing
Table 1: Technical data
M-A-F B-xx
Weight 1)
in kg
Approx. 235 1)
Width of brake pad
in mm
200
Surface of each brake pad
organic
in mm2
57,900
sinter metal
in mm2
53,500
Max. wear of each brake pad
in mm
8
Rated coefficient of friction 2)
μ =
0.4
Total brake piston surface - complete brake
in cm2
113
Volume for each brake caliper with 1 mm stroke
in cm3
11.3
Max. operating pressure
in bar
115
Thickness of brake disk 3)
in mm
30, 40, 50
Pressure connection
G 1/4
Drain port
G 1/8
Floating range on
axles
towards mounting surface
in mm
5
off the mounting surface
in mm
10
Min. diameter of brake disk ØDA
in mm
800
Operating temperature
in °C
-20 to +50
2) The friction coefficient each depends on the application resp. material of the brake pad; please consult with KTR.
3) Other thickness of brake disk available on request.
Table 2: Braking torque in Nm with brake disk Ø in mm
Brake disk Ø in mm
800
1500
2000
Braking torque in Nm
31200
67600
93600
1 Technical data

KTR-STOP®M-A-F B-xx
Operating/Assembly instructions
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Calculation of braking force/braking torque:
= 2FF cb
2
2,0D
FzM A
bb
−
=
Fb
Fc
Mb
z
DA
0.2
= Braking power in kN
= Clamping force in kN
= Braking torque in kNm
= Number of brakes
= Outside diameter of brake disk in m
= Width of brake pad in m
Calculation of brake disk:
Illustration 2: Assembly of brake
Table 2: Calculation of brake disk
DC max. = DA–420
Dav = DA- 200
1 Technical data

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Connection dimensions of brake
Illustration 3: Connection dimensions
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.
S T O P
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®M-A-F B-xx
Operating/Assembly instructions
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S T O P
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. Make absolutely sure to read through and observe the following safety indications.
•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 and 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
•had technical training
•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 M-A-F B-xx described in here corresponds to the state of the art 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 for 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 avoid
sticking together of the gaskets.
!
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.
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 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®M-A-F B-xx
Operating/Assembly instructions
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The brake is supplied in pre-assembled condition. Before assembly the brake has to be inspected for completen-
ess.
Components/subassemblies of brake –Type M-A-F B-xx
Compo-
nent/sub-
assembly
Quantity
Description
1
1
Caliper with components
2
1)
Distance plate
3
1
Base plate with
guide pin
4
2
Centering system
5
2
Pad retraction set movable
side
6
2
Brake pad
7
2
Pad retraction set on fixed
side
8
1 2)
Sensor
1) Number depends on thickness of brake disk.
2) Optionally available
Illustration 4: Components/subassemblies of brake
Component 2: Number of the spacer plate
Thickness of
brake disk
Number of spacer plates
30
2
40
1
50
-
Subassembly 1: Caliper with components
Compo-
nent
Quantity
Description
Illustration 5: Caliper with components
1.1
1
Brake caliper
(incl. piston cover)
1.2
4
DU sleeve
1.3
2
Pad retainer
1.4
2
Pad retainer
1.5
8
Cap screw
DIN EN ISO 4762 - 10.9
1.6
4
Screw plug
VSTI (acc. to DIN 908)
1.7
1
Sealing plug
1.8
1
Brake piston
1.9
1
Scraper
1.10
1
Gasket
1.11
1
Screw plug
VSTI (acc. to DIN 908)
1.12
1
Sealing plug
1.13
4
Scraper
4 Assembly
4.1 Components of the brake

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Subassembly 3: Base plate with guide pin
Compo-
nent
Quantity
Description
Illustration 6: Base plate with guide pin
3.1
1
Base plate
3.2
2
Guide pin
Subassembly 4: Centering system
Compo-
nent
Quantity
Description
Illustration 7: Centering system
4.1
1
Pin
4.2
1
Pressure spring
4.3
1
Disk
4.4
5
Hexagon nut
DIN EN ISO 4032
Subassembly 5: Pad retraction set movable side
Compo-
nent
Quantity
Description
Illustration 8: Pad retraction set movable side
5.1
1
Pin
5.2
1
Pressure spring
5.3
2
Hexagon nut
DIN EN ISO 4032
4 Assembly
4.1 Components of the brake

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Subassembly 7: Pad retraction set fixed side
Compo-
nent
Quantity
Description
Illustration 9: Pad retraction set on fixed side
7.1
1
Cap screw
DIN EN ISO 7379 - 10.9
7.2
1
Pressure spring
7.3
1
Sealing plug

To ensure the full braking power, the preparation for assembly needs to be carefully per-
formed.
•The connection plate for the brake as well as the brake disk have to be inspected for dimensional accuracy.
For that purpose investigate the connection dimensions, connection surfaces and tolerances as specified in
the drawing (see illustrations 1 to 3 and table 3).
•Clean and degrease the brake disk and mounting surfaces. Dirt can easily be removed by means of solvents.

The connection between connection surface and brake is defined as friction fit. Any resi-
dues 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

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Operating/Assembly instructions
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
KTR supplies brake pads free from asbestos and lead only.
If requested, we will provide you with the respective certificates.
The brake pads are each adapted to the application and delivered accordingly.
They can be distinguished as follows:
•organic material
•sinter 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 components only.
S T O P
In order to avoid any injuries always make use of proper lifting equipment.
!
The brake is mainly selected for mounting on vertically aligned brake disks (see illustration
3). With horizontally aligned brake disks (see illustration 1) the brake may only be aligned
upright.
There are M12 threads in the pad retainer to fasten an eye bolt serving to use lifting tools. The eye bolt is to be
dismounted 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 another lifting tool around
damageable components.

Before you start with the assembly check if a sensor has been mounted.
Remove it before assembly in order to avoid any damages.
•Insert the brake pads (component 6) fully into the brake caliper.
•Applying for the moveable side only:
Push back the brake pad and brake piston manually.
!
Please make sure that at least one screw plug (component 1.6) is removed when moving
back the brake piston. Afterwards re-assemble the screw plug.

If you want to use brake pads after having assembled the brake, it is necessary to disas-
semble the pad retainer (component 1.3 and 1.4) for that purpose (chapter 5.1).
4 Assembly
4.3 Brake pads
4.4 Assembly of the brake

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Operating/Assembly instructions
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•Mount the pad retraction set on the movable side (component 7) by shifting the pressure spring (component
7.2) onto the pin (component 7.1). Screw the hexagon screw with the pressure spring into the brake pad
against a stop.
•Seal the bore via the sealing plug (component 7.3).
•Mount the pad retraction set (component 5) by screwing the pin (component 5.1) into the brake pad against a
stop. Set the pressure spring (component 5.2) on the pin (component 5.1). Pre-stress the pressure spring
(component 5.2) with a hexagon nut (component 5.3) by adjusting the hexagon nut (component 5.3 to the di-
mension specified in illustration 10. Counter the hexagon nut with the second hexagon nut (component 5.3).
Thickness of brake disk 30 mm
Thickness of brake disk 40 mm
Thickness of brake disk 50 mm
Illustration 10: Setting of pad retraction set movable side
•Repeat this process with the pad retraction set on the moveable side of caliper (component 5).

Secure the screw connection (component 5.1 and 7.1) at the brake pad additionally against
working loose, e. g. conglutinating with Loctite (average strength).
•Insert the brake in the correct position towards the
connection plate. Hand-tighten the brake via the screws
first.
Illustration 11

To facilitate the assembly it is possible to fix
the position of the brake by one screw only
first. Swing in the brake until the second
screw can be assembled, too (see illustration
11).
•Screw the brake through the guide pins on the connection
plate via 2 screws and tighten them evenly gradually at the
tightening torque specified (see table 4).
Table 4: Tightening torques
Screw size
Tightening torque TAin Nm
10.9
12.9
Untreated and oiled
Greased with MoS2
Untreated and oiled
Greased with MoS2
M36
3300
2450
3800
2800
•Align the brake in centre to the brake disk.
•Make sure that the brake disk can rotate freely while not touching the brake pads or the caliper.
•Re-assemble the sealing plugs (component 7.3).
4 Assembly
4.4 Assembly of the brake

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
In order to avoid any contact between the brake disk and the brake resulting from thermal
expansion, the distance of the brake as per table 3 needs to be observed.
!
Make sure that the tolerances of the brake disk do not exceed the figures specified in illust-
ration 3.
•Optional component:
Assemble the sensor (component 8) according to chapter 6.2.

The centering systems need to be reset with initial assembly or after having replaced brake
pads or single parts, respectively. This is the only way to ensure that the gap between the
brake disk and the brake pad on the bottom side is set to the right value and the pad does
not touch on any side.

The centering systems need to be regularly reset with wear of the brake pads. For that pur-
pose repeat the complete chapter Setting/resetting of the centering system.
•Measure the gap between the brake disk and the brake pad on the bottom side via a feeler gauge.
•Set the gap to the value specified by screwing the hexagon nut marked with 1 in illustration 12 in the direc-
tion upwards or downwards.
•Counter the hexagon nut with the hexagon nut marked with 2 in illustration 12.
Illustration 12: Setting of centering system
4 Assembly
4.4 Assembly of the brake
4.5 Setting/resetting of the centering system

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Operating/Assembly instructions
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•Connect the pressure oil line to one of the pressure connections of the brake (see illustration 13 and 14). For
that purpose 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 Minimess coupling with a Minimess hose to the venting hole (see illustration 13 and 14), for that pur-
pose the screw plug needs to be removed beforehand. Discharge the end of the Minimess hose in a suitable
collection container.

The pressure connection on top serves for venting the brake. For a flushing system make
use of the pressure connection on top.
!
It is not recommended to use steel plugs for venting.
•Connect the leakage oil line to the brake (see illustration 13 and 14). For that purpose remove the sealing
plug beforehand.

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 13: Connections of the leakage oil lines/pressure lines
Illustration 14: Pressure connection of a
brake

Make sure that the connections and hoses are adapted to the brakes with regard to pres-
sure, 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
4.6 Pressure connection of a brake

KTR-STOP®M-A-F B-xx
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
If several brakes are assembled we recommend to connect the pressure connection for
each brake individually (in parallel) (see illustration 15).
Please note, if several brakes are connected in a series (see illustration 16), the braking
effect of all following brakes may become effective slightly delayed.
•Connect the pressure oil line to one of the pressure
connections of the brake (see illustration 14, 15 and
16). For that purpose remove the screw plug before-
hand.
•Mount a Minimess coupling with a Minimess hose to
the venting hole (see illustration 13, 15 and 16), for
that purpose the screw plug needs to be removed be-
forehand. Discharge the end of the Minimess hose in
a suitable collection 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 15: Pressure connec-
tion of several brakes (in paral-
lel)
Illustration 16:
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 the pressure connection on top.
!
With the parallel connection of brakes (see illustration 15) each brake needs to be vented
individually.
!
It is not recommended to use steel plugs for venting.
•Connect the leakage oil line to the brake (see illustration 13, 15 and 16). For that purpose remove the sealing
plug beforehand.

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.

Make sure that the connections and hoses are adapted to the brakes with regard to pres-
sure, 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
4.7 Pressure connection of several brakes

KTR-STOP®M-A-F B-xx
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
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.
!
Make sure that there is sufficient liquid in the hydraulic system during and after the venting
process (recommendation of liquid, see chapter 4.10).
•Put some pressure on the hydraulic system. This will allow the brake pads to fit on the brake disk.
!
The hydraulic system must never be operated at a higher pressure than the figures spe-
cified in the type plate of the brake or table 1. If any figures or types/sizes are changed, con-
sult 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 make sure that
the brake is fully secured against activating.
•Applying with the use of a sensor only:
Mount the sensor (component 8) according to chapter 6.2 instead of the screw plug (component 1.11).
•The brake pads have to be run in on the surface of the brake disk to achieve the nominal coefficient of friction.

Observe the instructions for run-in according to KTR-N.
!
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 deviating operating temperatures consult with KTR.
4 Assembly
4.8 Start-up of the brake
4.9 Recommendation of fluids to be used

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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 classes are
permitted:
•ISO 4406, class 18/16/13
Maintenance operations on the hydraulic system
In order to ensure a smooth operation of the overall system, the maintenance operations on the hydraulic system
(inspection of level and degree of dirt, replacing the hydraulic liquid resp. filter elements, etc.) have to be perfor-
med as per the manufacturer's operating instructions.
The system has to be flushed resp. 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.
!
Make sure that the entire brake/hydraulic system is depressurized.
S T O P
Parts released or falling down may cause injury to persons or damage on the machine.
Secure the components before disassembly.

If a sensor is used (component 8) it has to be removed before the brake is disassembled.
•Drain the hydraulic oil completely from the brake.
•Dispose of the hydraulic oil as per chapter 4.12.
•Disconnect the leakage oil and pressure oil line from the brake.
•Remove the 2-off screws serving for fixing the brake to the connection plate.
•Take out the brake.
4 Assembly
4.9 Recommendation of fluids to be used
4.10 Disassembly of the brake

KTR-STOP®M-A-F B-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
445145 EN
17 of 23
1
Please observe protection
note ISO 16016.
Drawn:
2022-12-20 Ka/Wie
Replacing:
Verified:
2022-12-21 Ka
Replaced by:
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.
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 resp. standards that apply.
•Metal resp. brake pads
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
Electric components have to be treated as electric 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.
!
Make sure that the entire brake system is depressurized.
S T O P
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 maintenance operation make sure that
the brake is fully secured against activating.
•Disassemble the pad holders on one side (component 1.3 and 1.4).
•Remove the pad retraction sets (component 5 and 7).
•Replace the brake pads that have worn off. Insert the brake pads (component 6) fully into the brake caliper or
the distance plate, respectively.
•Applying for the moveable side only:
Push back the brake pad and brake piston manually.
4 Assembly
4.11 Spares inventory, customer service addresses
4.12 Disposal
5 Maintenance
5.1 Replacement of brake pads

KTR-STOP®M-A-F B-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
445145 EN
18 of 23
1
Please observe protection
note ISO 16016.
Drawn:
2022-12-20 Ka/Wie
Replacing:
Verified:
2022-12-21 Ka
Replaced by:
!
Please make sure that at least one screw plug (component 1.6) is removed when moving
back the brake piston. Afterwards re-assemble the screw plug.
•Hand-tighten the pad holders (component 1.3 and 1.4) by each 2-off cap screws (component 1.5) for the time
being. Tighten the screws at the tightening torque TA= 890 Nm.

Please make sure that the pad holders of the brake have various heights.
•Mount the pad retraction set on the movable side (component 7) by shifting the pressure spring (component
7.2) onto the pin (component 7.1). Screw the pin with the pressure spring into the brake pad against a stop.
•Repeat this process with the pad retraction set on the moveable side of caliper (component 5).

Secure the screw connection (component 5.1 and 7.1) at the brake pad additionally against
working loose, e. g. conglutinating with Loctite (average strength).
•Repeat chapter 4.5 Setting/resetting of the centering system.
•Please make sure that the brake disk can rotate freely while not touching the brake pads or the brake caliper.

To facilitate the replacement of the brake pads you can unscrew the screws of the connec-
tion plate and remove 1 of the 2 screws alternatively. Swing the brake out of its position.

Please note chapter 4.4 Assembly of the brake.
•Before you reactivate the brake, observe chapter 4.8 Start-up of the brakes.
5 Maintenance
5.1 Replacement of brake pads

KTR-STOP®M-A-F B-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
445145 EN
19 of 23
1
Please observe protection
note ISO 16016.
Drawn:
2022-12-20 Ka/Wie
Replacing:
Verified:
2022-12-21 Ka
Replaced by:

To ensure the full braking power, both disassembly and assembly have to be performed at
the highest level of purity.
•Disassemble the brake, please observe chapter 4.10
Disassembly of brakes.
•Remove the pad retraction sets (component 5 and 7).
Illustration 17: KTR-STOP®M-A-F B-xx
!
Disassemble the pad rectraction sets
carefully since the springs are prestres-
sed.
•Take out the brake pads (component 6) and the distance
plates (component 2).
•Each untighten the bottom 3-off hexagon nuts of the
centering system (component 4) and unscrew the pins
(component 4.1) from the base plate (component 3.1).
!
The two hexagon nuts on top of the cen-
tering system (component 4) must not be
disassembled.
•Remove the brake caliper (component 1) from the guide
pin (component 3.2).
!
Inspect the components/subassemblies 2,
3 and 4 for any kind of damage; it may be
necessary to replace the components.
Afterwards remove dirt, grease and corro-
sion from the components.
•Connect the hydraulics to a pressure port (see illustration 13) of the caliper and make sure that all other
pressure ports are locked by screw plugs.
•Press the brake piston (component 1.8) carefully out of the brake caliper by using some hydraulic oil.
•Remove the gasket (component 1.10) and the scraper (component 1.9).

When removing the gaskets and scrapers make sure that the keyways in the caliper 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.
5 Maintenance
5.2 Maintenance of the brake / replacement of single parts

KTR-STOP®M-A-F B-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
445145 EN
20 of 23
1
Please observe protection
note ISO 16016.
Drawn:
2022-12-20 Ka/Wie
Replacing:
Verified:
2022-12-21 Ka
Replaced by:
!
Observe the manufacturer’s instructions
regarding the use of solvents.
Illustration 18: Caliper with components
!
Inspect the DU bushes (component 1.2)
and scrapers (component 1.13) for any
kind of damage, if necessary, the compo-
nents have to be replaced. Afterwards re-
move dirt, grease and corrosion from the
components.
•Insert new gaskets (component 1.10) and scrapers
(component 1.9) into the caliper. For that purpose the
components may be heart-shaped (see illustration 19).
!
The gasket and scraper have to be instal-
led in the right direction (see illustration
20).

With reassembly of the brake piston basi-
cally new gaskets and scrapers have to be
used, since their operativeness is no lon-
ger ensured due to wear and damages.
•Grease the gaskets and scrapers with hydraulic oil (see
illustration 20).
!
Oils and greases containing molybdenum disulphite or zinc sulphite additives must not be
used.
Illustration 19: Assembly of gasket and scraper
Illustration 20
!
Inspect the surfaces of the brake piston and the hole of the brake caliper 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 1.8) into the caliper and press it against a stop.
•Depending on the thickness of brake disk:
Fit the spacer plate (component 2). Number of distance plates are shown of in the table in chapter 4.1 Com-
ponents of the brake.
•After having disassembled the pin of the centering system (component 4), push the pin (component 4.1) with
the pressure springs into the brake caliper. Afterwards screw the hexagon nuts onto the pin.
5 Maintenance
5.2 Maintenance of the brake / replacement of single parts