KTR KTR-STOP RL Manual

KTR-STOP®RL
Size S and M
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44610 EN
1 of 16
2
Please observe protection
note ISO 16016.
Drawn:
2020-11-23 Shg
Replacing:
KTR-N dated 2011-11-12
Verified:
2020-11-23 Shg
Replaced by:
KTR-STOP®RL
Size S and M
KTR-STOP®RL (Rotor Lock) is a hydraulic mechanism serving for locking a ro-
tor positively by inserting a pin into a locking disk. The locking serves for preven-
ting a rotor standing still from starting.

KTR-STOP®RL
Size S and M
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44610 EN
2 of 16
2
Please observe protection
note ISO 16016.
Drawn:
2020-11-23 Shg
Replacing:
KTR-N dated 2011-11-12
Verified:
2020-11-23 Shg
Replaced by:
KTR-STOP®RL (Rotor Lock) was designed to be used as a locking device for rotors of wind power
stations. Within the scope of intended use a pin is pushed hydraulically into the bore that fits of a lo-
cking disk which prevents the rotor from rotating. This process may take place at standstill only. 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 KTR-STOP®RL 7
4.2 Preparation of assembly 8
4.3 Assembly of KTR-STOP®RL 8
4.4 Start-up of KTR-STOP®RL 10
4.5 Locking of KTR-STOP®RL 10
4.6 Recommendation of fluids to be used 11
4.7 Disassembly of KTR-STOP®RL 12
5Spares inventory, customer service addresses 12
6Disposal 12
7Maintenance of KTR-STOP®RL/replacement of single parts 13
8Accessories - Sensor 15
8.1 Technical data 15
8.2 Assembly / start-up 16
Table of contents

KTR-STOP®RL
Size S and M
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44610 EN
3 of 16
2
Please observe protection
note ISO 16016.
Drawn:
2020-11-23 Shg
Replacing:
KTR-N dated 2011-11-12
Verified:
2020-11-23 Shg
Replaced by:
Illustration 1: Size S
Illustration 2: Size M
Table 1: Technical data
S
M
Approx. weight
[kg]
90
153
Max. stroke
[mm]
80
80
Max. shear force FL
[kN]
2000
4000
Max. operating pressure
[bar]
250
250
Max. force fore stroke (F+)
[kN]
283
283
Max. force back stroke (F-)
[kN]
187
187
Piston diameter
[mm]
120
120
Piston surface fore stroke
[cm2]
113.10
113.10
Piston surface back stroke
[cm2]
74.61
74.61
Oil volume per 1 mm stroke
[cm3]
11.3
11.3
Oil volume with 75 mm stroke (full stroke)
[cm3]
848.2
848.2
Pressure port
1/4" BSP
1/4" BSP
!
Please note that the shear force refers to the Rotor Lock only.
Illustration 3: Diagramme - size S
Illustration 4: Diagramme - size M
2
D
FzM .eff
LL =
FL
ML
z
Deff.
= Shear force [kN]
= Lock torque [kNm]
= Quantity of KTR-STOP® RL
= Pitch circle diameter of locking disk [m]
1 Technical data

KTR-STOP®RL
Size S and M
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44610 EN
4 of 16
2
Please observe protection
note ISO 16016.
Drawn:
2020-11-23 Shg
Replacing:
KTR-N dated 2011-11-12
Verified:
2020-11-23 Shg
Replaced by:
Connection dimensions of housing
Illustration 5: Housing dimensions - size S
Illustration 6: Housing dimensions - size M
Connection dimensions of locking disk
Illustration 7: Locking disk
1 Technical data

KTR-STOP®RL
Size S and M
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44610 EN
5 of 16
2
Please observe protection
note ISO 16016.
Drawn:
2020-11-23 Shg
Replacing:
KTR-N dated 2011-11-12
Verified:
2020-11-23 Shg
Replaced by:
Please read through these operating/assembly instructions carefully before you start up the Rotor Lock.
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 Rotor Lock it has to be made sure that the
entire drive train is secured against accidental switch-on. You may be seriously hurt by ro-
tating parts. Please make absolutely sure to read through and observe the following safety
indications.
•All operations on and with the Rotor Lock 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 Rotor Lock.
•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 range of the Rotor Lock as long as it is in operation.
•Please secure the Rotor Lock against accidental operation. Please provide for the necessary protection de-
vices.
•Please make sure that the entire hydraulic system is depressurized.
You may only assemble, operate and maintain the Rotor Lock if you
•have carefully read through the operating/assembly instructions and understood them
•had technical training
•are authorized by your company
The Rotor Lock may only be used in accordance with the technical data (see chapter 1). Unauthorized modifica-
tions on the Rotor Lock 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 KTR-STOP®RL described in here correspond to the technical status at the time of printing of these as-
sembly/operating instructions.
2 Advice
2.1 General advice
2.2 Safety and advice symbols
2.3 General hazard warnings
2.4 Intended use

KTR-STOP®RL
Size S and M
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44610 EN
6 of 16
2
Please observe protection
note ISO 16016.
Drawn:
2020-11-23 Shg
Replacing:
KTR-N dated 2011-11-12
Verified:
2020-11-23 Shg
Replaced by:
The Rotor Lock is delivered in a preserved condition and can be stored in a closed, dry place during 12 months.
With proper storage conditions its properties remain unchanged up to 12 months.
If the Rotor Lock is stored over a longer period exceeding 12 months and after every transport, the corrosion pro-
tection needs to be renewed and operated over the full distance to prevent the gaskets from sticking together.
!
Humid storage rooms are not suitable.
Please make sure that condensation is not generated. The best relative air humidity is less
than 65 %.
Direct contact with metallic parts or dust, respectively, must be avoided.
!
In order to avoid any injuries and any kind of damage please always make use of proper
transport and lifting equipment.
The Rotor Lock is packed differently each depending on quantity and kind of transport. Unless otherwise contrac-
tually agreed, packaging will follow the in-house packaging specifications of KTR.
The Rotor Lock is supplied in pre-assembled condition. Before assembly the Rotor Lock has to be inspected for
completeness.
!
Please make sure that the components are not damaged when unpacking them.
3 Storage, transport and packaging
3.1 Storage
3.2 Transport and packaging
4 Assembly

KTR-STOP®RL
Size S and M
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44610 EN
7 of 16
2
Please observe protection
note ISO 16016.
Drawn:
2020-11-23 Shg
Replacing:
KTR-N dated 2011-11-12
Verified:
2020-11-23 Shg
Replaced by:
Components of KTR-STOP®RL
Compo-
nent
Quantity
Description
19
1
Fastening pin
20
8
Hexagon screw
DIN EN ISO 4014 - 10.9
21
8
Disk DIN EN ISO 7089
23
1 1)
Sensor
50
1
KTR-STOP®RL (pre-assembled)
1) Optionally available
Illustration 8: Components of KTR-STOP®RL
4 Assembly
4.1 Components of KTR-STOP®RL

KTR-STOP®RL
Size S and M
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44610 EN
8 of 16
2
Please observe protection
note ISO 16016.
Drawn:
2020-11-23 Shg
Replacing:
KTR-N dated 2011-11-12
Verified:
2020-11-23 Shg
Replaced by:
Components of KTR-STOP®RL
Compo-
nent
Quantity
Description
Compo-
nent
Quantity
Description
1
1
Piston
13
1
Back-up ring (type BU)
2
2
Guide ring (piston)
16
3
Screw plug DIN 908
3
1
Piston gasket
17
2
Eye bolt DIN 580
4
1
Locking pin
18
1
Cap screw
DIN EN ISO 4762 - 10.9
5
1
Piston cover
6
1
Guide ring (piston cover)
19
1
Fastening pin
7
1
Rod sealing ring
20
8
Hexagon screw
DIN EN ISO 4014 - 10.9
8
1
Scraper
9
1
Connection flange
21
8
Disk DIN EN ISO 7089
10
1
Dowel pin
22
1
Air breather
11
1
Lock nut
23
1 1)
Sensor
12
1
Gasket
1) Optionally available
Illustration 9: Components of KTR-STOP®RL

To ensure the full power of locking, the preparation for assembly needs to be performed
carefully.
•The housing for the Rotor Lock as well as the locking disk have to be inspected for dimensional accuracy. For
that purpose please investigate the connection dimensions, connection surfaces and tolerances as mentioned
in the drawing (see illustrations 5 to 7).
•Please clean the locking disk and mounting surfaces.
STOP
In order to avoid any injuries please always make use of proper lifting equipment.
There are eye bolts on the face of the Rotor Lock serving to use lifting devices.
!
In order to avoid any damages on the Rotor Lock, never twist a rope or any other lifting tool
around damageable components such as sensors, etc.
4 Assembly
4.1 Components of KTR-STOP®RL
4.2 Preparation of assembly
4.3 Assembly of KTR-STOP®RL

KTR-STOP®RL
Size S and M
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44610 EN
9 of 16
2
Please observe protection
note ISO 16016.
Drawn:
2020-11-23 Shg
Replacing:
KTR-N dated 2011-11-12
Verified:
2020-11-23 Shg
Replaced by:

The eye bolts can be removed after assembly of the Rotor Lock. Please store them in a safe
place. Avoid any kind of dirt; for that purpose you should use sealing plugs.

Before you start with the Rotor Lock assembly, please make sure that the fastening pin
(component 19) has been removed (see picture 11).
•The piston (component 1) needs to be inserted into the
lock bolt (component 4) as far as possible. For that purpo-
se press the piston manually into the lock bolt or via hyd-
raulic pressure on the pressure port “I” as far as possible.
Here the pressure port “O” must neither be closed nor
connected to a hydraulic system preventing a free pres-
sure reduction on “O” (see illustration 10).
•Please make sure that oil may escape from the pressure
connection „O“.
•Please make sure that the surface of the connection flange
(component 9) is in parallel with the locking disk.
Illustration 10: Pressure ports
•Lubricate the bore of the housing with Molykote MoS2.
•Insert the Rotor Lock into the bore of the housing.
•Lock the Rotor Lock by means of the hexagon screws M 16 - DIN EN ISO 4014 - 10.9 (component 20) and the
disks (component 21). Hand-tighten them first.
•Tighten the hexagon screws crosswise at the tightening torque TA= 290 Nm.
•Assembly of the sensor (sensor is optionally available).

If a sensor (component 23) is used, chapter 8 needs to be observed.
•Connect the pressure oil lines to the pressure ports „I“ and „O“.

To avoid any contact between the locking disk and the Rotor Lock, a minimum distance of
5 mm needs to be observed in fully locked position (see illustration 11). In fully unlocked
position the maximum distance of 15 mm needs to be observed in every case (see illustrati-
on 12).
Illustration 11
Illustration 12
IO
4 Assembly
4.3 Assembly of KTR-STOP®RL

KTR-STOP®RL
Size S and M
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44610 EN
10 of 16
2
Please observe protection
note ISO 16016.
Drawn:
2020-11-23 Shg
Replacing:
KTR-N dated 2011-11-12
Verified:
2020-11-23 Shg
Replaced by:

Before start-up and after each operation on the Rotor Lock the hydraulic system has to be
generally vented and filled up or re-filled with fluid.
Repeat venting the Rotor Lock several times a year, since any air in the hydraulic system
may have an influence on the operativeness of the Rotor Lock.
!
Please make sure that there is sufficient liquid in the hydraulic system during and after the
venting process (recommendation of liquid, see chapter 4.6).
•Activating the pressure ports reciprocally several times allows you to vent the hydraulic system of the Rotor
Lock.
!
The hydraulic system must never be operated at a higher pressure than the figures mentio-
ned in the type plate of the Rotor Lock or table 1. If any figures or types/sizes are changed,
please consult with KTR.
!
To prevent serious injuries of your hand, never keep your fingers between locking disk and
locking pin while locking the Rotor Lock.
Before every maintenance operation make sure that the Rotor Lock is fully secured against
activating.
STOP
To prevent injuries and any kind of damage on the Rotor Lock or, as an example, your wind
power stations etc., the mechanical locking device of the Rotor Lock has to be mounted
before the maintenance or service operations are started with.
•Screw the fastening pin (component 19) into the connection flange (component 9) against a stop (see illustra-
tion 13).
Illustration 13: Locking the KTR-STOP®RL
4 Assembly
4.4 Start-up of KTR-STOP®RL
4.5 Locking of KTR-STOP®RL