KTR-Group KTR-STOP YAW M B Series Manual

KTR-STOP®
YAW M B-xx
Operating/Assembly instructions
KTR-N
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Edition:
445120 EN
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YAW M
YAW M B-xx is a disk brake in an active design serving for transmitting a brake
force onto a brake disk in order to decelerate or stop its rotation, respectively, or
keep it at standstill.

KTR-STOP®
YAW M B-xx
Operating/Assembly instructions
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445120 EN
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The KTR-STOP®YAW M B-xx brake was designed for use as a stop brake. 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 6
4.1 Components of the brake 6
4.2 Preparation of assembly 7
4.3 Brake pads 7
4.4 Assembly of the brake 8
4.5 Pressure port of a brake 9
4.6 Pressure port of several brakes 10
4.7 Start-up of the brake 11
4.8 Recommendation of liquids to be used 12
4.9 Disassembly of the brake 13
5Disposal 13
6Maintenance 14
6.1 Replacement of brake pads 14
6.2 Maintenance of the brake / replacement of single parts 14
6.3 Maintenance and service 16
7Spares inventory, customer service addresses 16
Table of contents

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YAW M B-xx
Operating/Assembly instructions
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Illustration 1: Dimensional drawing
Table 1: Technical data
YAW M B-xx
Weight
[kg]
Approx. 63 1)
Width of brake pad
[mm]
108
Surface of each brake pad
[mm2]
20,300
Max. wear of each brake pad (material: organic)
[mm]
7
Rated coefficient of friction 2)
[μ =]
0.4
Total brake piston surface - complete brake
[cm2]
254
Volume for each brake caliper with 1 mm stroke
[cm3]
25.4
Pressure port
G 1/4
Oil bleed
G 1/4
Max. clamping force
[kN]
203
Max. operating pressure
[bar]
160
Thickness of brake disk
[mm]
30 - 50
External assembly of brake
Min. diameter of brake disk ØDA
[mm]
500
Internal assembly of brake
Min. diameter of brake disk ØDi
[mm]
900
Operating temperature
[°C]
-20 to +50
2) The friction coefficient each depends on the application or material of the brake pad; please consult with KTR.
Illustration 2: Diagramme
 = 2
cb FF
2
av
bb D
FzM =
Fb
Fc
Mb
z
Dav
= Brake power [kN]
= Clamping force [kN]
= Braking torque [kNm]
=Number of brakes with each brake pad
= Effective diameter of brake [m]
1 Technical data

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YAW M B-xx
Operating/Assembly instructions
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Dimensions of brake disk
Illustration 3: Internal assembly of brake
Illustration 4: External assembly of brake
Table 2: Calculation of brake disk
Internal assembly of brake
External assembly of brake
46000200
2
.min +−= avaviDDD
10036000
2+−= iav DD
102−= Aav DD
250
.min += iA DD
240
.max −= Ai DD
Connection dimensions of brake
Illustration 5: Connection dimensions
1 Technical data

KTR-STOP®
YAW M B-xx
Operating/Assembly instructions
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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.
•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 YAW M 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®
YAW M B-xx
Operating/Assembly instructions
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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 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.
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 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.
The brake is supplied in pre-assembled condition. Before assembly the brake has to be inspected for completen-
ess.
Components/component assemblies of brake –Type YAW M B-xx
Compo-
nent/suba
ssembly
Quantity
Description
Illustration 6:
Components
of the brake
1
2
Housing with compo-
nents
2
2
Brake pad
3
1)
Distance plate
4
1)
Gasket
1) Number depends on thickness of
brake disk.
3 Storage, transport and packaging
3.1 Storage
3.2 Transport and packaging
4 Assembly
4.1 Components of the brake

KTR-STOP®
YAW M B-xx
Operating/Assembly instructions
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Subassembly 1 - Housing with components
Compo-
nent
Quantity
Description
Illustration
7:
Housing
with single
parts
1.1
1
Housing
1.2
2
Brake piston
1.3
2
Scraper
1.4
2
Back-up ring
1.5
2
O-ring
1.6
2
Screw plug
VSTI (acc. to
DIN 908)
1.7
1
Eye bolt DIN 580
1.8
1
Screw plug

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 investigate the connection dimensions, connection surfaces and tolerances as specified in
the drawing (see illustrations 1 to 5 and table 2).
•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.
!
Observe the manufacturer’s instructions regarding the use of solvents.

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 are highly sensitive to grease and oil which means that they cannot be cleaned.
Brake pads with such dirt need to be replaced and disposed of.

We 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. Make
sure to replace by original parts only.
4 Assembly
4.1 Components of the brake
4.2 Preparation of assembly
4.3 Brake pads

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YAW M B-xx
Operating/Assembly instructions
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STOP
In order to avoid any injuries please always make use of proper lifting equipment.
On the reverse side of the brakes there are threads for eye bolts serving for using lifting devices. The eye bolts
should be disassembled after assembly of the brake and stored in a safe place.
!
In order to avoid any damages on the brake, never twist a rope or another lifting tool around
damageable components.
•Before you start with the assembly each one dust protection
plug needs to be removed from both housings (component
1).
•Insert the brake pads into the housing as deep as possible.
Compress the brake pads and brake pistons manually.
•Please make sure that the connection surface is in parallel
with the brake and the tolerances as per illustration 5 are
observed.
Illustration 8: Dust protection plug
•Push a housing in the correct position of the connection plate and fasten the housing via 2 cap screw M10.
•Insert the O-ring (component 4) in the counterbore.
•Depending on the thickness of brake disk:
Put the distance plate (component 3) onto the housing and insert the second gasket (component 4) into the
indentation of the distance plate.
•Fit the second housing in the correct position onto the first
housing resp. distance plate.
•Screw the brake to the connection plate by means of 8-off
screws and tighten them hydraulically evenly gradually at 1/3
and afterwards 2/3 of the tightening torque TA(see table 3).
Afterwards tighten the screws at the full tightening torques
specified in table 3 hydraulically. For any other tightening
procedures please consult with KTR.
Illustration 9: Tightening of connection screws

Preferably use the order specified in illustration
9.
Table 3: Tightening torques
Screw size
Tightening torque TA[Nm] –10.9
Untreated and oiled
Greased with MoS2
M27
1496
1100
•Align the brake in centre to the brake disk.
•Make sure that the brake disk can rotate freely while not touching 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 2 needs to be observed.
!
Make sure that the tolerances of the brake disk do not exceed the figures specified in illust-
ration 5.
4 Assembly
4.4 Assembly of the brake

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YAW M B-xx
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•Connect the pressure oil line to the pressure ports of the brake (see illustration 10 and 11). For that purpose
remove the screw plug beforehand.
!
The hydraulic lines have to be rinsed before connecting to the brake to prevent any partic-
les 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 10
and 11), 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 ports on top serve for venting the brake. For a wash-up system make use of
one of the pressure ports on top.

Always connect the brake consisting of two halves to a pressure line (see illustration 11),
since the brake disk is loaded with the full braking power on one side in case if one half of
the brake fails.
!
It is not recommended to use steel plugs for venting.
•Connect the drain line to the brake (see illustration 10 and 11). For that purpose remove the sealing plug befo-
rehand.

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. 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 10: Connections of the drain lines/pressure lines
Illustration 11: 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 ac-
cordingly.
4 Assembly
4.5 Pressure port of a brake

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YAW M 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 12).
Please note, if several brakes are connected in a series (see illustration 13), the braking
effect of all following brakes may become effective slightly delayed.
•Connect the pressure oil line to the pressure ports of the brake (see illustration 10, 12 and 13). For that purpo-
se 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 dama-
ged 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 10,
12 and 13), for that purpose the screw plug needs to be removed beforehand. Discharge the end of the minia-
ture measuring hose in a suitable collection container.

The pressure ports on top serve for venting the brake. For a wash-up system make use of
one of the pressure ports on top.

Always connect the brake consisting of two halves to a pressure line (see illustration 12 and
13), since the brake disk is loaded with the full braking power on one side in case if one half
of the brake fails.
!
With the parallel connection of brakes (see illustration 12) 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 10, 12 and 13). 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 on every single brake. Since higher pressures (5 bar at the maximum)
are not generated, a pneumatic hose may be used, too. Inspect the brake for leakages regu-
larly.
!
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 12: Pressure port of several brakes (in parallel)
Illustration 13: Pressure ports of several brakes (in a series)
4 Assembly
4.6 Pressure port of several brakes

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YAW M B-xx
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
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 ac-
cordingly.

Before start-up and after each operation on the brake the hydraulic system has to be gene-
rally vented.
Repeat venting the brake several times a year, since any air in the hydraulic system may
affect the operation of the brake and the plant.
!
Please make sure that there is sufficient liquid in the hydraulic system during and after the
venting process (recommendation of liquid, see chapter 4.8).
•Switch on the hydraulic system for a short while to make sure that the brake is rinsed 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 9 to 12).
•Dispose of the hydraulic oil of the collection container as per chapter 5.
•The active brake described in here does not require any gap to release the brake or brake pads, respectively.
•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 make sure that the brake is fully secured against acti-
vating.
•The brake pads have to be ground in on the surface of the brake disk to achieve the nominal coefficient of
friction.
4 Assembly
4.6 Pressure port of several brakes
4.7 Start-up of the brake

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YAW M B-xx
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
You may only use mineral hydraulic liquids meeting the demands 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 from -20 °C to +50 °C (-4 °F to +122 °F) of the brake
components have to be adhered to. 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 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.
The KTR hydraulic systems are provided with a 10-µm inline filter as a standard.
In order to ensure the reliability of the system, only 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 smooth operation of the overall system, the maintenance operations on the hydraulic system
(inspection of level and degree of dirt, replacing the hydraulic liquid or filter elements, etc.) have to be performed
as per the manufacturer's operating instructions.
The system has to be rinsed or vented after each replacement of the hydraulic liquid.
!
Adverse reactions may be generated by mixing different liquids or liquids of various manu-
facturers.

Please contact the manufacturer of mineral oils if you intend to replace the hydraulic liquid.
4 Assembly
4.8 Recommendation of liquids to be used

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YAW M B-xx
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•Release the pressure fully from the hydraulic system.
!
Make sure that the entire brake system is depressurized.
STOP
Parts released or falling down may cause injury to persons or damage on the machine.
Secure the components before disassembly.
•Remove the highest located screw plug (component 1.6) from the venting hole (see illustrations 10 to 13).
•Drain the hydraulic oil completely from the brake.
•Dispose of the hydraulic oil as per chapter 5.
•Disconnect the drain and pressure oil line from the brake.
•Screw the screw plugs (component 1.6) in all pressure ports or venting holes (see illustration 10 to 13).
•Remove the 8-off screws (M27) serving for fixing the brake to the connection plate.
•Take out the brake.
•Depending on the thickness of brake disk
Remove the distance plate after having taking out the first half of the brake.
•Remove the 2-off cap screws (M10) serving for fixing the second half of brake to the connection plate.
•Take out the second half of brake (component 1).

There are one resp. two gaskets between the two brake halves. Make sure not to lose them.
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.
•Hydraulic oil
Hydraulic oils have to be collected in suitable tanks and disposed of by a waste disposal company.
4 Assembly
4.9 Disassembly of the brake
5 Disposal

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YAW M B-xx
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
Brake pads having a balance of pad height of less than 2 mm have to be replaced by return.
•Release the pressure fully from the hydraulic system.
!
Make sure that the entire brake system is depressurized.
STOP
Parts released or falling down may cause injury to persons or damage on the machine.
Secure the components before disassembly.
•Remove the 7-off or 8-off screws serving for fixing the brake to the connection plate.
•Swing the upper half of the brake from the brake disk by using the remaining screw as a joint.
•Replace the brake pad that has worn off. Insert the brake pad into the housing as deep as possible. Compress
the brake pad and brake piston manually.

Before you swing the brake half back to its original position, please note chapter 4.2 Prepa-
ration of assembly.
•Repeat this chapter with the half of brake at the bottom.
•Screw the brake to the connection plate by means of 8-off screws and tighten them hydraulically evenly
gradually at 1/3 and afterwards 2/3 of the tightening torque TA(see table 3). Afterwards tighten the screws at
the full tightening torques specified in table 3 hydraulically. For any other tightening procedures please consult
with KTR.

Please note chapter 4.4 Assembly of the brake.
•Before you reactivate the brake, please observe chapter 4.7 Start-up of the brakes.

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 4.9 Disassembly of brakes.

One O-ring is located between the two halves of the brake. Make sure not to lose it.
•Take out the brake pads (component 2).
•Press the brake pistons (component 1.2) out of the housing (component 1.1) by means of some hydraulic
pressure on the pressure port.
•Remove the gaskets (component 1.4 and 1.5) and the scraper (component 1.3).
6 Maintenance
6.1 Replacement of brake pads
6.2 Maintenance of the brake / replacement of single parts

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YAW M B-xx
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
When removing the gaskets and scrapers make sure that the keyways in the housing are
not damaged.
•The components have to be cleaned from dirt, grease and corrosion protection. The components can easily be
cleaned by means of solvents. Afterwards dry the components.
!
Observe the manufacturer’s instructions regarding the use of solvents.
•Insert gaskets (component 1.4 and 1.5) and scrapers (component 1.3) into the housing (component 1.1). For
that purpose the components may be heart-shaped (see illustration 14).
!
The gaskets and scrapers have to be installed in the right direction (see illustration 15).

With a reassembly of the brake piston basically new gaskets and scrapers have to be used,
since their operativeness is no longer ensured due to wear and damages.
•Grease the gaskets and scrapers with hydraulic oil (see illustration 15).
!
Oils and greases containing molybdenum disulphite or zinc sulphite additives must not be
used.
Illustration 14: Assembly of O-ring, support ring
and scraper
Illustration 15
!
Inspect the surfaces of the brake pistons and the holes 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
leakages.
•Insert the brake pistons (component 1.2) in the housing (component 1.1) and press them against a stop.
•Mount the (new) brake pad. Insert the brake pad into the housing as deep as possible. Compress the brake
pad and brake piston manually.
•Repeat chapters 4.2 to 4.7.
6 Maintenance
6.2 Maintenance of the brake / replacement of single parts

KTR-STOP®
YAW M B-xx
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
445120 EN
16 of 16
1
Please observe protection
note ISO 16016.
Drawn:
2019-11-18 Shg/Wie
Replacing:
---
Verified:
2019-11-22 Shg
Replaced by:
KTR-STOP®YAW M B-xx is a low-maintenance brake. We recommend to perform a visual inspection and an
operational testing on the brake at least once a year. Here you should put special emphasis on leakages, corro-
sion, wear of brake pads and the condition of the screw connections.

If you realize any irregularities, perform repairs accordingly.
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.
6 Maintenance
6.3 Maintenance and service
7 Spares inventory, customer service addresses