KTR-Group KTR-STOP XS F B Series Manual

KTR-STOP®XS-xx-F B-xx
Operating/Assembly instructions
KTR-N
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Edition:
44536 EN
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KTR-STOP®XS-xx-F B-xx
XS-xx-F B-xx is a spring-actuated brake in a floating calliper design serving to
generate a brake force on a brake disk in order to decelerate a plant’s movement
or stop it, respectively, or keep it at standstill.

KTR-STOP®XS-xx-F B-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44536 EN
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3
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note ISO 16016.
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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 6
3.1 Storage 6
3.2 Transport and packaging 6
4Assembly 7
4.1 Components of the brake 7
4.2Preparation 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 Setting/Resetting of the brake 16
4.10 Recommendation of fluids to be used 17
4.11 Disassembly of the brake 18
4.12 Spares inventory, customer service addresses 18
4.13 Disposal 19
5Maintenance 19
5.1 Replacement of brake pads 19
5.2 Maintenance of the brake / replacement of single parts 20
5.3 Maintenance and service 23
6Accessories - Sensor 24
6.1 Technical Data „State/wear sensor“ 24
6.2 Assembly / start-up 25
Table of contents

KTR-STOP®XS-xx-F B-xx
Operating/Assembly instructions
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Illustration 1: Dimensional
drawing
Table 1: Technical data
XS-xx-F B-xx
Weight
[kg]
Approx. 19 1)
Width of brake pad
[mm]
70
Surface of each brake pad
organic
[mm2]
8000
Powder metal
[mm2]
5800
Max. wear of each brake pad
[mm]
5
Rated Coefficient of friction 2)
[μ =]
0.4
Total brake piston surface - complete brake
[cm2]
11
Volume for each brake calliper with 1 mm stroke
[cm3]
1.1
Max. operating pressure
[bar]
200
Width 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
away from mounting surface
[mm]
5
Min. diameter of brake disk ØDA
[mm]
300
Operating temperature
[°C]
- 20 to + 50
1 Technical data

KTR-STOP®XS-xx-F B-xx
Operating/Assembly instructions
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Table 2: Clamping force, loss of preload force, opening pressure and weight
Brake type 3)
Clamping force
Fc[kN]
Loss of power 4)
[%]
Opening
pressure [bar]
Braking torque [Nm] with
brake disk Ø [mm]
315
560
800
KTR-STOP®XS-2-F B-xx
2
11
30
180
370
570
KTR-STOP®XS-3-F B-xx
3
5.5
40
270
560
850
KTR-STOP®XS-4-F B-xx
4
3
50
360
750
1140
KTR-STOP®XS-5-F B-xx
5
8.5
70
450
940
1420
KTR-STOP®XS-6-F B-xx
6
6.5
80
540
1130
1710
KTR-STOP®XS-7-F B-xx
7
4.5
90
640
1320
1990
KTR-STOP®XS-8-F B-xx
8
16.5
120
730
1510
2280
KTR-STOP®XS-9-F B-xx
9
12
130
820
1700
2570
KTR-STOP®XS-10-F B-xx
10
10
140
910
1890
2850
KTR-STOP®XS-11-F B-xx
11
8.5
150
1000
2080
3140
KTR-STOP®XS-12-F B-xx
12
11
160
1090
2270
3420
KTR-STOP®XS-13-F B-xx
13
9.5
170
1190
2460
3710
KTR-STOP®XS-14-F B-xx
14
8.5
180
1280
2650
3990
KTR-STOP®XS-15-F B-xx
15
8
190
1370
2840
4280
2) The friction coefficient each depends on the application or material of the brake pad; please consult with KTR.
3) Other brake types on request
4) With a stroke of 1 mm (0.5 mm wear of brake pad on each side)
= 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]
Calculation of brake disk:
Illustration 2: Assembly of brake
Table 3: Calculation of brake disk
DC max. = DA- 195
Dav = DA- 86
1 Technical data

KTR-STOP®XS-xx-F B-xx
Operating/Assembly instructions
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44536 EN
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Connection dimensions of brake
Illustration 3: Connection dimensions
Please read through these operating/assembly instructions carefully 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
preventing bodily injuries or serious bodily injuries that
may result in death.
!
Warning of product damages
This symbol indicates notes which may contribute to
preventing material or machine damage.

General advice
This symbol indicates notes which may contribute to
preventing adverse results or conditions.
1 Technical data
2 Advice
2.1 General advice
2.2 Safety and advice symbols

KTR-STOP®XS-xx-F B-xx
Operating/Assembly instructions
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STOP
With assembly, operation and maintenance of the brake it has to be made sure that the
entire 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 indications.
•All operations on and with the brake have to be performed taking into account "safety first".
•Please 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.
•Please secure the brake against accidental contact. Please provide for the necessary protection devices.
•Please 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-xx-F B-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 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 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 quantity 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
3.1 Storage
3.2 Transport and packaging

KTR-STOP®XS-xx-F B-xx
Operating/Assembly instructions
KTR-N
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Edition:
44536 EN
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The brake is supplied in pre-assembled condition. Before assembly the brake has to be inspected for
completeness.

The brake is generally supplied with the transport lock mounted.
The screw plug (component 1.9) is attached to the brake in bulk.
Components/component assemblies of brake –Type XS-xx-F B-xx
Component/
component
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
Brake pad
6
2
Spring clamp
7
2
Cap screw
DIN EN ISO 4762 - 12.9
8
2
Pad retraction set
9
1 2)
Sensor
1) Quantity depends on thickness of brake disk.
2) Optionally available
Illustration 4: Components/component assemblies of brake
Component assembly 1: Caliper with components
Component
Quantity
Description
Illustration 5: Housing with components
1.1
1
Brake caliper
1.2
1
Brake piston
1.3
1
Scraper
1.4
1
Gasket
1.5
1
Gasket
1.6
1
Set of disk springs
1.7
1
Setting nut
1.8
1
O-ring
1.9
1
Screw plug VSTI (acc. to
DIN 908)
1.10
2
Pad retainer
1.11
2
Pad retainer
1.12
8
Cap screw
DIN EN ISO 4762 - 10.9
1.13
2
Screw plug VSTI (acc. to
DIN 908)
1.14
1
Drain plug (nylon)
1.15
2
Blind rivet
DIN EN ISO 15975
1.16
1
Drain plug (nylon)
1.17
4
DU bushing
1.18
4
Scraper
1.19
1
Disk
4 Assembly
4.1 Components of the brake

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Component assembly 3: Base plate with guide pin
Component
Quantity
Description
Illustration 6: Base plate with guide pin
3.1
1
Base plate
3.2
2
Guide pin
Component assembly 4: Centering system
Component
Quantity
Description
Illustration 7: Centering system
4.1
1
Pin
4.2
1
Pressure spring
4.3
5
Hexagon nut
DIN EN ISO 4032
4.4
1
Washer
4 Assembly
4.1 Components of the brake

KTR-STOP®XS-xx-F B-xx
Operating/Assembly instructions
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Component assembly 8: Pad retraction set for housing
Component
Quantity
Description
Illustration 8: Pad retraction set for housing
8.1
1
Pin
8.2
1
Pressure spring

To ensure the full braking power, the preparation for assembly needs to be performed
carefully.
•The connection plate for the brake as well as the brake disk have to be inspected for dimensional accuracy.
For that purpose please 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

KTR-STOP®XS-xx-F B-xx
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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
•powder metal
!
Brake pads made of organic material 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.
In contrast to organic brake pads, brake pads made of powder metal can be cleaned from grease and oil as long
as they have not fully soaked with grease and oil.

We would recommend to store the brake pads in their package as long as possible to
protect them from any kind of dirt.
!
Brake pads which have worn off to the wear limit have to be replaced immediately. Please
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 brakes 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.
•Inspect the position of the setting nut (component 1.7). If necessary, set it to the right dimension (see
illustration 17).
•Insert the brake pads (component 5) fully into the brake caliper.

If you want to use brake pads after having assembled the brake, it is necessary to
disassemble the pad holder (component 1.10 and 1.22) for that purpose (chapter 5.1).
•Secure the brake pad at the bottom via the spring clamps (component 6) and the cap screws (component 7).
•Mount the pad retraction set (component 8) by screwing the pin (component 8.1) into the brake pad against a
stop.
4 Assembly
4.3 Brake pads
4.4 Assembly of the brake

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Operating/Assembly instructions
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
Secure the screw connection (component 8.1) on 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
for the time being.
Illustration 9

To facilitate the assembly it is possible to fix
the position of the brake by one screw only
for the time being. Swing in the brake until the
balance of the screws can be assembled, too
(see illustration 9).
•Screw the brake through the guide pins to the connection
plate via 2 screws and tighten them evenly stepwise 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 caliper.

In order to avoid any contact between the brake disk and the brake resulting from thermal
expansion, the distance of the brake according to table 3 needs to be observed.
!
Please make sure that the tolerances of the brake disk do not exceed the figures specified
in illustration 3.
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 bottom side 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
purpose 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 12.
Illustration 10: Setting of gap
Illustration 11: Setting of centering system

The gap between brake disk and brake pad needs to be 0.5 mm on both sides to ensure the
brake power.
4 Assembly
4.5 Setting/resetting of the centering system

KTR-STOP®XS-xx-F B-xx
Operating/Assembly instructions
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Edition:
44536 EN
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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 rinsed before connecting to the brake to prevent any
particles from getting into the brake. If the lines are not rinsed 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 port 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.
•Connect the drain line to the brake (see illustration 12 and 13). For that purpose remove the drain plug
beforehand.

In order to locate a leakage immediately, it is recommended to use a transparent hose and
collection container. Since higher pressures (5 bar at the maximum) are not generated, a
pneumatic hose may be used, too. Please inspect the brake regularly for leakages.
!
Extreme leakages have to be removed immediately. Oil which has escaped has to be
removed completely, since oil remains may vaporize on hot components and ignite.
Illustration 12: Connections of the drain lines/pressure lines
Illustration 13: Pressure port 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
4.6 Pressure port of a brake

KTR-STOP®XS-xx-F B-xx
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
If several brakes are assembled we recommend to connect the pressure port 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 12, 14 and 15). For
that purpose remove the screw plug beforehand.
•Mount a miniature measuring coupling with a
miniature measuring hose to the venting hole (see
illustration 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
collection container.
!
The hydraulic lines have to be rinsed
before connecting to the brake to
prevent any particles from getting into
the brake. If the lines are not rinsed
sufficiently, the gaskets may be
damaged and the operation of the brake
is no longer ensured.
Illustration 14: Pressure port
of several brakes (in parallel)
Illustration 15: Pressure port
of several brakes (in a series)
!
The pressure port on top serves for venting the brake. For a wash-up system please make
use of the pressure 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 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 bar at the maximum) are not generated, a
pneumatic hose may be used, too. Please inspect the brake regularly for leakages.
!
Extreme leakages have to be removed immediately. Oil which has escaped has to be
removed completely, 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

KTR-STOP®XS-xx-F B-xx
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
Before start-up and after each operation on the brake the hydraulic system has to be
generally vented.
Repeat bleeding 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).
•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 1.13)
needs to be screwed into the venting hole (see illustrations 12 to 15).
•Dispose of the hydraulic oil of the collection container as per chapter 4.13.
•Put the opening pressure (see table 2) on the hydraulic system to relieve the locking device for assembly.
!
The hydraulic system must never be operated at a higher pressure than the figures
specified 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 locking 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.
•Remove the screw with the disk (assembly lock, see
illustration 16) from the adjusting nut (component 1.7).
Bild 16: Assembly lock

Afterwards store the assembly lock (screw with
disk) in a safe place since it will be required
again.
•Screw the screw plug (component 1.9) into the setting nut
(component 1.7).
•Applying with the use of a sensor only:
Mount the sensor (component 9) according to chapter 6.2
instead of the screw plug (component 1.9).
•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

KTR-STOP®XS-xx-F B-xx
Operating/Assembly instructions
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Edition:
44536 EN
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
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. Before you reset the
brake, the centering system needs to be set first.
For that purpose repeat the complete chapters Setting/resetting of the centering system and
afterwards Setting/resetting of the brake.
•Remove the O-ring (component 1.8) and the screw plug (component 1.9).
•Applying with the use of a sensor only:
Remove the sensor (component 9).
•Please put the opening pressure (see table 2) on the hydraulic system to make sure that the brake pads lift off
the brake disk.

Please note chapter 4.8 Start-up of brake.
•Screw the screw with the disk (assembly lock, see
illustration 16) into the setting nut (component 1.7).
•Release the pressure from the hydraulic system.
•Measure the gap between the brake disk and the brake pad on
the side of the housing via a feeler gauge.
•Set the gap to 0.5 mm by screwing the setting nut either
upwards or downwards.
•Applying for the resetting of the brake only (wear of brake
pad):
With a wear of the brake pad (0.5 mm wear for each brake
pad) of 1 mm the setting nut needs to be screwed in by ½
revolution.
•Insert the O-ring (component 1.8) between the housing and the
setting nut.
Illustration 17: Setting of setting nut

The gap between brake disk and brake pad needs to be 0.5 mm on both sides to ensure the
brake power.
•Applying with the use of a sensor only:
Mount the sensor (component 9) according to chapter 6.2 instead of the screw plug (component 1.9).
4 Assembly
4.9 Setting/Resetting of the brake

KTR-STOP®XS-xx-F B-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44536 EN
17 of 25
3
Please observe protection
note ISO 16016.
Drawn:
2020-03-26 Shg/Wie
Replacing:
KTR-N dated 2017-12-19
Verified:
2020-03-26 Shg
Replaced by:
!
You may only use mineral hydraulic fluids meeting the demands of DIN 51524. KTR
recommends those fluids 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 TX32
Tellus TX46
Tellus Artic
Tellus TX68
Mobil
DTE 13M
DTE 15M
-
DTE 16M
Hydro Texaco
Rando HDZ32
Rando HDZ46
Rando Ashless 8401
Rando HDZ68
Valvoline
Ultramax HVLP32
Ultramax HVLP46
-
Ultramax HVLP68

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
temperature. 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 20/17/12
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
manufacturers.

Please contact the manufacturer of mineral oils if you intend to replace the hydraulic fluid.
4 Assembly
4.10 Recommendation of fluids to be used

KTR-STOP®XS-xx-F B-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44536 EN
18 of 25
3
Please observe protection
note ISO 16016.
Drawn:
2020-03-26 Shg/Wie
Replacing:
KTR-N dated 2017-12-19
Verified:
2020-03-26 Shg
Replaced by:
STOP
In order to avoid any personal injuries, protect the brake by means of the assembly lock.
•Remove the screw plug (component 1.9) or the sensor (component 9) from the setting nut (component 1.7).
•Put the opening pressure (see table 2) onto the hydraulic system.
•Hand-tighten the screw with the disk (assembly lock, see illustration 16) into the setting nut (component 1.7).
•Release the pressure fully from the hydraulic system.
!
Please 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.
•Remove the screw plug located at the highest point (component 1.13) from the venting hole (see
illustrations 12 to 15).
•Drain the hydraulic oil completely from the brake.
•Dispose of the hydraulic oil as per chapter 4.13.
•Disconnect the drain and pressure oil line from the brake.
•Screw the screw plugs (component 1.13) 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 operational readiness 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
4.11 Disassembly of the brake
4.12 Spares inventory, customer service addresses

KTR-STOP®XS-xx-F B-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44536 EN
19 of 25
3
Please observe protection
note ISO 16016.
Drawn:
2020-03-26 Shg/Wie
Replacing:
KTR-N dated 2017-12-19
Verified:
2020-03-26 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
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 5 mm have to be replaced by return.
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 locking 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.
•Remove the screw plug (component 1.9) or the sensor (component 9) from the setting nut (component 1.7).
•Put the opening pressure (see table 2) onto the hydraulic system.
•Hand-tighten the screw with the disk (assembly lock, see illustration 16) into the setting nut (component 1.7).
•Release the pressure fully from the hydraulic system.
•Inspect the position of the setting nut (component 1.7). If necessary, set it to the right dimension (see
illustration 17).
•Disassemble the pad holders on one side (component 1.10 and 1.11).
•Remove the pad retraction sets (component 8) and the spring clamps (component 6), respectively.
•Replace the brake pads that have worn off. Insert the brake pads (component 5) fully into the brake caliper or
the distance plate, respectively.
•Hand-tighten the pad holders (component 1.10 and 1.11) by each 2-off cap screws (component 1.12) for the
time being. Tighten the screws at the tightening torque TA= 71 Nm.

Please make sure that the pad holders of the housing have various heights.
4 Assembly
4.13 Disposal
5 Maintenance
5.1 Replacement of brake pads

KTR-STOP®XS-xx-F B-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44536 EN
20 of 25
3
Please observe protection
note ISO 16016.
Drawn:
2020-03-26 Shg/Wie
Replacing:
KTR-N dated 2017-12-19
Verified:
2020-03-26 Shg
Replaced by:
•Secure the brake pad on the fixed side via the spring clamps (component 6) and the cap screws
(component 7).
•Mount the pad retraction set (component 8) by screwing the pin (component 8.1) into the brake pad against a
stop.

Secure the screw connection (component 8) on the brake pad additionally against working
loose, e. g. conglutinating with Loctite (average strength).
•Repeat chapter 4.5 Setting/re-adjustment of the centering system and chapter 4.9 Setting/re-adjustment of the
brake.
•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
connection plate and remove 1 out of the 2 screws alternatively. Swing the brake out of its
position.

Please note chapter 4.4 Assembly of brake.
•Before you reactivate the brake, please observe chapter 4.8 Start-up of the brake.

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 4.11
Disassembly of the brake.
•Remove the pad retraction sets (component 8) and the
spring clamps (component 6), respectively.
•Take out the brake pads (component 5) 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 brake caliper (component 1) from the guide
pin (component 3).
Illustration 18: KTR-STOP®XS-xx-F B-xx
!
Inspect the components/component
assemblies 2, 3 and 4 for any kind of
damages; it may be necessary to replace
the components.
Afterwards remove dirt, grease and
corrosion from the components.
5 Maintenance
5.1 Replacement of brake pads
5.2 Maintenance of the brake / replacement of single parts