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

KTR-STOP®XS-A-F B-xx
Operating/Assembly instructions
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KTR-STOP®XS-A-F B-xx
XS-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®XS-A-F B-xx
Operating/Assembly instructions
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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 5
2.4 Intended use 5
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 port of a brake 13
4.7 Pressure port of several brakes 14
4.8 Start-up of the brake 15
4.9 Recommendation of liquids to be used 16
4.10 Disassembly of the brake 17
4.11 Spares inventory, customer service addresses 17
4.12 Disposal 17
5Maintenance 18
5.1 Replacement of brake pads 18
5.2 Maintenance of the brake / replacement of single parts 19
5.3 Maintenance and service 21
6Accessories - Sensor 22
6.1 Technical data „Pre-/end wear sensor” 22
6.2 Assembly / start-up 23
Table of contents

KTR-STOP®XS-A-F B-xx
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Illustration 1:
KTR-STOP®XS-A-F B-xx
(dimensional drawing)
Table 1: Technical data
XS-A-F B-xx
Weight
[kg]
Approx. 18 1)
Width of brake pad
[mm]
70
Surface of each brake pad
organic
[mm2]
8,000
sinter metal
[mm2]
5,800
Max. wear of each brake pad
[mm]
5
Rated coefficient of friction 2)
[μ =]
0.4
Total brake piston surface - complete brake
[cm2]
15.9
Volume for each brake caliper with 1 mm stroke
[cm3]
1.59
Max. clamping force
[kN]
16.5
Max. operating pressure
[bar]
105
Thickness of brake disk
[mm]
20 - 30
Pressure port
G 1/8
Oil bleed
G 1/8
Floating range on axles
towards mounting surface
[mm]
5
off the mounting surface
[mm]
5
Min. diameter of brake disk ØDA
[mm]
300
Operating temperature
[°C]
- 20 up to + 50
2) The friction coefficient each depends on the application or material of the brake pad; please consult with KTR.
Table 2: Braking torque [Nm] with brake disk Ø [mm]
Brake disk Ø [mm]
315
560
800
Braking torque [Nm]
1510
3120
4710
= 2FF cb
2
D
FzM av
bb =
Fb
Fc
Mb
z
Dav
= Brake power [kN]
= Clamping force [kN]
= Braking torque [kNm]
= Number of brakes
= Effective diameter of brake [m]
1 Technical data

KTR-STOP®XS-A-F B-xx
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Calculation of brake disk:
Illustration 2: Assembly of brake
Table 3: Calculation of brake disk
DC max. = DA- 195
Dav = DA- 86
Connection dimensions of brake
Illustration 3: KTR-STOP®XS-A-F B-xx (connection dimensions)
1 Technical data

KTR-STOP®XS-A-F B-xx
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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.
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. Please 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
•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 XS-A-F B-xx described in here corresponds to the technical status at the time of printing of these
operating/assembly instructions.
2 Advice
2.1 General advice
2.2 Safety and advice symbols
2.3 General hazard warnings
2.4 Intended use

KTR-STOP®XS-A-F B-xx
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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 protection needs to be renewed
and the brake has to be activated over the full braking distance in order to prevent the gaskets from sticking toge-
ther.
!
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.
3 Storage, transport and packaging
3.1 Storage
3.2 Transport and packaging

KTR-STOP®XS-A-F B-xx
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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 XS-A-F B-xx
Compo-
nent/
subas-
sembly
Quantity
Description
Illustration 4: KTR-STOP®XS-A-F
1
1
Housing with components
2
1)
Distance plate
3
1
Base plate with guide pin
4
2
Centering system
5
2
Pad retraction set
6
2
Spring clamp
7
2
Cap screws
DIN EN ISO 4762 –10.9
8
2
Brake pad
9
1 2)
Sensor
1) Number depends on thickness of brake disk.
2) Optionally
Component 2: Number of the spacer plate
Thick-
ness
of
brake
disk
Quantity
Distance
plate
(pos. 2)
20
1
30
-
4 Assembly
4.1 Components of the brake

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Subassembly 1: Housing with components
Compo-
nent
Quantity
Description
Illustration 5: Housing with single parts
1.1
1
Brake caliper
(incl. piston cover)
1.2
4
DU bushing
1.3
2
Pad retainer
1.4
2
Pad retainer
1.5
8
Cap screw
DIN EN ISO 4762 –10.9
1.6
2
Screw plug
VSTI (acc. to DIN 908)
1.7
1
Screw plug
1.8
1
Screw plug
1.9
1
Screw plug
1.10
1
Brake piston
1.11
1
Scraper
1.12
1
Gasket
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
4 Assembly
4.1 Components of the brake

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Subassembly 4: Centering system
Subassembly 5: Pad retraction set for housing
Compo-
nent
Quantity
Description
Compo-
nent
Quantity
Description
4.1
1
Pin
5.1
1
Cap screw DIN EN ISO 4762
4.2
1
Pressure spring
5.2
1
Pressure spring
4.3
5
Hexagon nut
DIN EN ISO 4032
5.3
1
Washer
4.4
1
Washer
5.4
1
Bush
Illustration 7: Centering system
Illustration 8: Pad retraction
set for housing

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 plate and brake is defined as 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.
!
Please 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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
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
•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 parts only.
STOP
In order to avoid any injuries please always make use of proper lifting equipment.
A thread M8 is located on the back of the brake 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 any other lifting tool
around damageable components such as sensors, centering systems, 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.
•Insert the brake pads (component 8) 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).
•Mount the pad retraction set for housings (component 5) by shifting the pressure spring (component 5.2) with
the disk (component 5.3) onto the sleeve (component 5.4). Screw the hexagon screw (component 5.1) with the
pressure spring, the disk and the sleeve into the brake pad against a stop.
4 Assembly
4.3 Brake pads
4.4 Assembly of the brake

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
Secure the screw connection (component 5.1) on the brake pad additionally against working
loose, e. g. conglutinating with Loctite (average strength).
•Mount the spring clamps (component 6).
•Insert the brake in the correct position to the
connection plate. Hand-tighten the brake via the
screws first.
Illustration 9

To facilitate the assembly it is pos-
sible to fix the position of the brake
by one screw only first. Swing in the
brake until the balance of the screws
can be assembled, too (see illustrati-
on 9).
•Screw the brake to the connection plate by means
of 2 screws and tighten them evenly gradually at
the tightening torque specified (see table 4).
Table 4: Tightening torques
Screw size
Tightening torque TA[Nm]
10.9
12.9
Untreated and oiled
Greased with MoS2
Untreated and oiled
Greased with MoS2
M16
290
215
340
250
•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 housing.

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.
•Applying with the use of a sensor only:
Mount the sensor (component 9) according to chapter 6.2.
4 Assembly
4.4 Assembly of the brake

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
The centering system needs to be reset with initial assembly or after having replaced brake
pads or single parts, respectively. Only in this way it is ensured that the gap between the
brake disk and the brake pad on the side of the counter plate is set to the right value and the
pad does not touch on any side.

The centering system has to be reset regularly with wear of the brake pads. For that purpo-
se 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 0.5 mm or the figure x requested (see illustration 10), respectively, by screwing the hexagon
nut marked with 1 in illustration 11 either upwards or downwards.
•Counter the hexagon nut with the hexagon nut marked with 2 in illustration 11.
•Secure the pin (component 4.1) via the hexagon nut (component 4.3).
•Screw the bolt (component 4.1) into the base plate (component 3.1). The screw depth in the base plate
must be 10 mm.
Illustration 10: Setting of gap
Illustration 11: Setting of centering system
4 Assembly
4.5 Setting/resetting of the centering system

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•Connect the pressure oil line to one of the pressure ports of the brake (see illustration 12 and 13). 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 miniature measuring coupling with a miniature measuring hose to the venting hole (see illustration 12
and 13), 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 connection on top serves for venting the brake. For a wash-up system please
make use of the pressure port on top.
!
It is not recommended to use steel plugs for venting.
Illustration 12: Connections of the leakage oil lines/pressure lines
Illustration 13: Pressure connection of a brake
•Connect the drain line to the brake (see illustration 12 and 13). For that purpose remove the drain plug before-
hand.

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.

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
4.6 Pressure port of a brake

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
If several brakes are assembled we recommend to connect the pressure connection for
each brake individually (in parallel) (see illustration 14).
Please note, if several brakes are connected in a series (see illustration 15), the braking
effect of all following brakes may become effective slightly delayed.
•Connect the pressure oil line to one of the pressure
ports of the brake (see illustration 13, 14 and 15). For
that purpose remove the screw plug beforehand.
Illustration 14: Pressure port
of several brakes (in parallel)
Illustration 15: Pressure port
of several brakes (in a series)
!
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 lon-
ger ensured.
•Mount a miniature measuring coupling with a minia-
ture measuring hose to the venting hole (see illustra-
tion 13, 14 and 15), 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 pressure connection on top serves
for venting the brake. For a wash-up
system please make use of the pres-
sure port on top.
!
With the parallel connection of brakes (see illustration 14) each brake needs to be vented
individually.
!
It is not recommended to use steel plugs for venting.
•Connect the drain line to the brake (see illustration 12, 14 and 15). For that purpose remove the screw 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.

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
4.7 Pressure port of several brakes

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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 4.9).
•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 (component 1.6)
needs to be screwed in the venting hole (see illustrations 12 to 15).
•Dispose of the hydraulic oil of the collection container as per chapter 4.12.
•Put some pressure on the hydraulic system. This will allow the brake pads to fit onto 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,
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.
•The brake pads have to be ground in on the surface of the brake disk to achieve the nominal coefficient of
friction.

Please observe the instructions for grinding-in according to KTR-N.
4 Assembly
4.8 Start-up of the brake

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!
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 fluids (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 please consult with
KTR.
Viscosity
We would recommend a viscosity range from 20 to 220 mm2/s (cSt) of the hydraulic fluid 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 fluid, 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 fluid or filter elements, etc.) have to be performed as
per the manufacturer's operating instructions.
The system has to be scavenged or vented after each replacement of the hydraulic fluid.
!
Adverse reactions may be generated by mixing different fluids or fluids of various manufac-
turers.

Please contact the manufacturer of mineral oils if you intend to replace the hydraulic fluid.
4 Assembly
4.9 Recommendation of liquids to be used

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!
Make sure that the entire brake/hydraulic system is depressurized.
STOP
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 9) 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.
•Screw the screw plugs (component 1.6) into all pressure ports or venting holes (see illustrations 12 to 15).
•Remove the 2-off screws serving for fixing the brake to the connection plate.
•Take out the brake.
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 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
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.
4 Assembly
4.10 Disassembly of the brake
4.11 Spares inventory, customer service addresses
4.12 Disposal

KTR-STOP®XS-A-F B-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
445118 EN
18 of 23
1
Please observe protection
note ISO 16016.
Drawn:
2020-12-03 Shg/Mro
Replacing:
---
Verified:
2020-12-03 Shg
Replaced by:

Brake pads having a balance of pad height of less than 5 mm have to be replaced by return.
!
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.
!
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.
•Disassemble the pad holders on one side (component 1.3 and 1.4).
•Remove the pad retraction sets (component 5) and the spring clamps (component 6), respectively.
•Replace the brake pads that have worn off. Insert the brake pads (component 8) 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.
!
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= 71 Nm.

Please make sure that the pad holders of the brake have various heights.
•Mount the pad retraction sets for housings (component 5) by shifting the pressure spring (component 5.2) with
the disk (component 5.3) onto the sleeve (component 5.4). Screw the hexagon screw (component 5.1) with the
pressure spring, the disk and the sleeve into the brake pad against a stop.

Secure the screw connection (component 5.1) on the brake pad additionally against working
loose, e. g. conglutinating with Loctite (average strength).
•Secure the brake pad on the fixed side via the spring clamps (component 6) and the cap screws (component
7).
•Repeat chapter 4.5 Setting/resetting of the centering system.
•Make sure that the brake disk can rotate freely while not touching the brake pads or the housing.

To facilitate the replacement of the brake pads you can unscrew the screws of the connec-
tion plate and remove 1 out 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, please observe chapter 4.8 Start-up of the brake.
5 Maintenance
5.1 Replacement of brake pads

KTR-STOP®XS-A-F B-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
445118 EN
19 of 23
1
Please observe protection
note ISO 16016.
Drawn:
2020-12-03 Shg/Mro
Replacing:
---
Verified:
2020-12-03 Shg
Replaced by:

To ensure the full braking power, both disas-
sembly and assembly have to be performed at
the highest level of purity.
Illustration 16: KTR-STOP®XS-A-F B-xx
•Disassemble the brake, please observe chapter 4.10 Disas-
sembly of the brake.
•Remove the pad retraction sets (component 5) and the
spring clamps (component 6), respectively.
!
Disassemble the pad rectraction sets carefully
since the springs are prestressed (about 20 N).
•Take out the brake pads (component 8) and the distance
plate (component 2).
•Untighten each the two hexagon nuts on top of the centering
system (component 4) and remove them along with the disk
and the pressure spring.
•Remove the housing with single parts (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 ne-
cessary to replace the components. After-
wards remove dirt, grease and corrosion from
the components.
•Connect the hydraulics to a pressure port (see illustration
12) of the housing and make sure that all other pressure
ports are locked by screw plugs.
•Press the brake piston (component 1.10) carefully out of the
housing by means of some hydraulic pressure.
•Remove the gasket (component 1.12) and the scraper
(component 1.11).
Illustration 17: Housing with single parts

When removing the gasket and scraper please
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.
!
Please observe the manufacturer’s instructions regarding the use of solvents.
5 Maintenance
5.2 Maintenance of the brake / replacement of single parts

KTR-STOP®XS-A-F B-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
445118 EN
20 of 23
1
Please observe protection
note ISO 16016.
Drawn:
2020-12-03 Shg/Mro
Replacing:
---
Verified:
2020-12-03 Shg
Replaced by:
•Insert a new gasket (component 1.12) and a new scraper (component 1.11) into the housing.
For that purpose the components may be heart-shaped (see illustration 18).
!
The gasket and scraper have to be installed in the right direction (see illustration 19).

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 gasket and the scraper with hydraulic oil (see illustration 19).
!
Oils and greases containing molybdenum disulphite or zinc sulphite additives must not be
used.
Illustration 18: Assembly of gasket and scraper
Illustration 19
!
Inspect the surfaces of the brake piston and the hole of the housing 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 leaka-
ges.
•Insert the brake piston (component 1.10) in the housing and press it against a stop.
•Fit the distance plate (component 2).
•After you have disassembled the pin of the centering system (component 4), screw each the 3-off hexagon
nuts at the bottom onto the pin. Afterwards screw the pin into the base plate by 10 mm.
•Counter the pin with the hexagon nut marked with 3 in illustration 21.
•Fit the pre-assembled unit carefully onto the guide pins.

Please make sure that the centering system (component 4) is not damaged.
5 Maintenance
5.2 Maintenance of the brake / replacement of single parts