KTR KTR-STOP XS-xx A-xx-xx Operating/Mounting Instructions

KTR-STOP® XS-xx A-xx-xx
Operating/Assembly instructions
KTR-N
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Edition:
45126 EN
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1
KTR-STOP® XS-xx A-xx-xx
XS-xx A-xx-xx is a spring-actuated brake in a fixed calliper design serving to generate a brake force onto a brake disk in order to decelerate a plant’s movement
or stop it, respectively, or keep it at standstill.
Please observe protection
note ISO 16016.
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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.
Table of contents
1
Technical data
3
2
Advice
5
2.1
2.2
2.3
2.4
General advice
Safety and advice symbols
General hazard warnings
Intended use
5
5
5
5
Storage, transport and packaging
6
3.1
3.2
6
6
3
4
5
6
Storage
Transport and packaging
Assembly
6
4.1 Components of the brake
4.2 Preparation of assembly
4.3 Brake pads
4.4 Assembly of the brake
4.5 Pressure port of a brake
4.6 Pressure port of several brakes
4.7 Start-up of the brake
4.8 Setting/Re-setting of the brake
4.9 Recommendation of liquids to be used
4.10 Disassembly of the brake
4.11 Spares inventory, customer service addresses
4.12 Disposal
7
8
8
9
10
12
13
14
15
16
17
17
Maintenance
17
5.1
5.2
5.3
17
18
20
Replacement of brake pads
Maintenance of the brake / replacement of single parts
Maintenance and service
Accessories - Sensor
6.1
6.2
20
Technical Data „State/wear sensor“
Assembly / start-up
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Operating/Assembly instructions
1
45126 EN
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1
Technical data
Illustration 1: Dimensional drawing
Table 1: Technical data
Weight
Width of brake pad
organic
powder
metal
Surface of each brake pad
Max. wear of each brake pad
Rated coefficient of friction 2)
Total brake piston surface - complete brake
Volume for each brake caliper with 1 mm stroke
Max. operating pressure
Pressure port
Oil bleed
Min. diameter of brake disk ØDA
Operating temperature
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[kg]
[mm]
[mm2]
XS-xx A-xx-xx
Approx. 20
70
8,000
[mm2]
5,800
[mm]
[μ =]
[cm2]
[cm3]
[bar]
5
0.4
22
2.2
200
G 1/8
G 1/8
300
-20 to +50
[mm]
[°C]
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45126 EN
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Technical data
Table 2: Clamping force, loss of preload force and opening pressure
Brake type 3)
KTR-STOP® XS-2 A-xx-xx
KTR-STOP® XS-3 A-xx-xx
KTR-STOP® XS-4 A-xx-xx
KTR-STOP® XS-5 A-xx-xx
KTR-STOP® XS-6 A-xx-xx
KTR-STOP® XS-7 A-xx-xx
KTR-STOP® XS-8 A-xx-xx
KTR-STOP® XS-9 A-xx-xx
KTR-STOP® XS-10 A-xx-xx
KTR-STOP® XS-11 A-xx-xx
KTR-STOP® XS-12 A-xx-xx
KTR-STOP® XS-13 A-xx-xx
KTR-STOP® XS-14 A-xx-xx
KTR-STOP® XS-15 A-xx-xx
Clamping
force
Fc [kN]
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Loss of power 4)
[%]
Opening pressure [bar]
11.0
5.5
3.0
8.5
6.5
4.5
16.5
12.0
10.0
8.5
11.0
9.5
8.5
8.0
30
40
50
70
80
90
120
130
140
150
160
170
180
190
Braking torque [Nm] with
brake disk Ø [mm]
315
560
800
180
370
570
270
560
850
360
750
1140
450
940
1420
540
1130
1710
640
1320
1990
730
1510
2280
820
1700
2570
910
1890
2850
1000
2080
3140
1090
2270
3420
1190
2460
3710
1280
2650
3990
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 (1 mm wear of brake pad)
Fb = Fc  2  
Mb = z  Fb 
Dav
2
Fb
Fc
Mb
z
Dav
=
=
=
=
=
Brake power [kN]
Clamping force [kN]
Braking torque [kNm]
Number of brakes
Effective diameter of brake [m]
Table 3: Calculation of brake disk
DC max. = DA – 195
Dav = DA - 86
Connection dimensions of brake
Illustration 2: Connection dimensions
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Advice
2.1 General advice
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.
2.2 Safety and advice symbols
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.
2.3 General hazard warnings
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".
• 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.
2.4 Intended use
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 A-xx-xx described in here corresponds to the technical status at the time of printing of
these operating/assembly instructions.
Please observe protection
note ISO 16016.
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Storage, transport and packaging
3.1 Storage
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 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 %.
!
3.2 Transport and packaging
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.
4
Assembly
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 1.13) is attached to the brake in bulk.
Please observe protection
note ISO 16016.
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Assembly
4.1 Components of the brake
Components/subassemblies of brake – Type XS-xx A-xx-xx
Component/suba
ssembly
1
2
3
4
Quantity
Description
2
4
2
2 1)
Housing with components
Pad retraction set
Brake pad
Sensor
1) Optionally available
Illustration 3: Components/subassemblies of brake
Subassembly 1: Housing with components
Component
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
Quantity
Description
1
1
1
1
1
1
1
1
2
Housing
Scraper
Gasket
Gasket
Brake piston
Set of disk springs
Setting nut
O-ring
Pad retainer
Cap screw
DIN EN ISO 4762 - 10.9
Screw plug VSTI (acc. to
DIN 908)
Screw cap
Screw plug VSTI (acc. to
DIN 908)
1.10
4
1.11
2
1.12
1
1.13
1
Illustration 4: Housing with single parts
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Assembly
4.1 Components of the brake
Subassembly 2: Pad retraction sets
Component
2.1
2.2
2.3
Quantity
1
1
1
Description
Pin
Pressure spring
Disk
Illustration 5: Pad retraction set
4.2 Preparation of assembly

To ensure the full braking power, the preparations for assembly need to be carefully performed.
• The connection plate or the stand 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 and 2 and table 3).
• Clean and degrease the brake disk and mounting surfaces. Dirt can easily be removed by means of solvents.

The connection between connection surface and brake is defined as frictional connection.
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.
!
4.3 Brake pads

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.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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Assembly
4.4 Assembly of the brake
!
If one half of the brake has to be mounted under pressure (without transport lock) for
reasons of space, please consult with KTR.
In order to avoid any injuries please always make use of proper lifting equipment.
STOP
!

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 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 12).
• Insert the brake pads (component 3) fully into the housing.

If you want to insert brake pads after having assembled the brake, it is necessary to disassemble the pad holders (component 1.14) for that purpose (chapter 5.1).
• Mount the pad retraction sets (component assembly 2) by screwing the screw (component 2.1) with the pressure spring (component 2.2) into the brake pad.
• Hand-tighten the screw.
• Insert the protective plug (component 2.3).

Secure the screw connection (component 2.1) on the brake pad additionally against working
loose, e. g. conglutinating with Loctite (average strength).
• Insert the first half of the brake (component 1) in the correct position towards the connection plate or stand,
respectively (see illustration 6).
•
Mount the 4-off connection screws and lock them at the tightening torques specified in table 4.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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45126 EN
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Assembly
4.4 Assembly of the brake
• Repeat this process withthe second half of brake.

To facilitate the assembly it is possible to fix
the position of the brake by one connection
screw only first. You should preferably insert
the connection screw marked with 1 in illustration 6. Swing in the brake until the balance of
the screws can be assembled, too (see illustration 6).
Illustration 6
Table 4: Tightening torques of the connection screws
Tightening torque TA [Nm] – 10.9
untreated and oiled
302
Screw size
M16

!
Tightening torque TA [Nm] – 10.9
lubricated with MoS2
224
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 illustration 2.
4.5 Pressure port of a brake
• Connect the pressure oil line to one of the pressure ports of the brake (see illustration 7 and 8). 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 penetrating 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 7
and 8), 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 8),
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.
!
Please observe protection
note ISO 16016.
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Assembly
4.5 Pressure port of a brake
• Connect the drain line to the brake (see illustration 7 and 8). For that purpose remove the sealing plugs beforehand.

If no drain line is connected, a vacuum may be generated inside the brake which will damage the gaskets.
!
Never give any pressure on the drain line. Gaskets and scrapers will be destroyed in this
way.

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 completely removed, since oil remains may vaporize on hot components and ignite.
Illustration 7: Connections of the drain lines/pressure lines

Illustration 8: Pressure port of a brake
Please make sure 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.
Please observe protection
note ISO 16016.
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Assembly
4.6 Pressure port of several brakes

If several brakes are assembled we recommend to connect the pressure port for each brake
individually (in parallel) (see illustration 9).
Please note, if several brakes are connected in a series (see illustration 10), the braking
effect of all following brakes may set in slightly delayed.
• Connect the pressure oil line to the pressure ports
of the brake (see illustration 8, 9 and 10). For that
purpose remove the screw plugs beforehand.
!
The hydraulic lines have to be rinsed
before connecting to the brake to prevent any particles from penetrating 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 8, 9 and 10), for that purpose the screw
plug needs to be removed beforehand. Discharge
the end of the miniature measuring hose in a suitable collection container.
Illustration 9: Pressure port of
several brakes (in parallel)
Illustration 10: Pressure port
of several brakes (in a series)
!
The pressure port on top serves 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 9 and
10), 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 9) 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 8, 9 and 10). For that purpose remove the screw caps beforehand.

If no drain line is connected, a vacuum may be generated inside the brake which will damage the gaskets.
!
Never give any pressure on the drain line. Gaskets and scrapers will be destroyed in this
way.

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.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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Assembly
4.6 Pressure port of several brakes
!

Severe leakages have to be removed immediately. Oil which has escaped has to be completely removed, since oil remains may vaporize on hot components and ignite.
Please make sure 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.
4.7 Start-up of the brake

!
Before start-up and after each operation on the brake the hydraulic system has to be generally 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 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 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 1.11)
needs to be screwed in the venting hole (see illustrations 9 and 10).
• Dispose of the hydraulic oil of the collection container as per chapter 4.12.
• Put the opening pressure (see table 2) on the hydraulic system to relieve the assembly lock.
!
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 applying the brake in order to
prevent serious injuries of your hands. Before every maintenance operation make sure that
the brake is fully secured against activating.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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45126 EN
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1
Assembly
4.7 Start-up of the brake
• Remove the screw with the disk (assembly lock, see illustration
11) on both sides from the from the brake piston (component
1.5).

Afterwards store the assembly lock (screw with
disk) in a safe place since it will be required
again later.
• Screw the screw plug (component 1.13) on both sides into the
setting nut (component 1.7).
• Applying with the use of a sensor only:
Mount the sensor (component 4) according to chapter 6.2
instead of the screw plug (component 1.13).
• The brake pads have to be ground in on the surface of the
brake disk to achieve the nominal coefficient of friction.

Bild 11: Assembly lock
Please observe the instructions for grinding-in according to KTR-N.
4.8 Setting/Re-setting of the brake

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.

As soon as the status wear of sensor is indicated resp. with a wear of pad of 2 mm the brake must
be readjusted. 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 on both sides (component 1.13).
• Applying with the use of a sensor only:
Remove the sensor (component 4).
• 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 4.7 Start-up of brake.
Please observe protection
note ISO 16016.
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Assembly
4.8 Setting/Re-setting of the brake
• Screw the screw with the disk (assembly lock, see illustration
11) on both sides into the brake piston (component 1.5).
• Release the pressure from the hydraulic system.
• Measure the gap between the brake disk and the brake pad on
both sides via a feeler gauge.
• Set the gap to 0.5 mm on both sides by screwing the setting
nut either upwards or downwards.
Applying for re-setting the brake only (wear of brake pad):
The brake must immediately be reset if the status wear of sensor
is indicated resp. with a wear on the brake pad of 2 mm. For that
purpose screw in the setting nut (component 1.7) by about half a
revolution per 1 mm of wear.
• Insert the O-ring (component 1.8) on both sides between the
housing and the setting nut (component 1.7).
Illustration 12: Setting of adjusting 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 4) according to chapter 6.2 instead of the screw plug (component 1.13).
4.9 Recommendation of liquids to be used
You may only use mineral hydraulic liquids meeting the specifications of DIN 51524. KTR
recommends those liquids corresponding to DIN 51524-3.
!
KTR recommends the following liquids (other manufacturers may be selected):
Manufacturer
Mineral oil
Castrol
Shell
Mobil

Standard
-20 °C to +40 °C
10 °C to 60 °C
(-4 °F to +104 °F)
(50 °F to 140 °F)
Hyspin HVI 32
Hyspin HVI 46
Tellus S2 VX32
Tellus S2 VX46
DTE 10 Excel 32
DTE 10 Excel 46
Special
-30 °C to +20 °C
30 °C to 70 °C
(-22 °F to +68 °F)
(86 °F to 158 °F)
Hyspin HVI 68
Tellus S4 VX32
Tellus S2 VX68
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 liquid with operating temperature. The viscosity during starting should not exceed 500 mm2/s and the viscosity during operation must 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.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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Assembly
4.9 Recommendation of liquids to be used
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 class 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 manufacturers.
Please contact the manufacturer of mineral oils if you intend to replace the hydraulic liquid.
4.10 Disassembly of the brake
STOP
In order to avoid any personal injuries, protect the brake on both sides by means of the assembly lock.
• Remove the screw plug (component 1.13) or the sensor (component 4) on both sides from the setting nut
(component 1.7).
• Put the opening pressure (see table 2) on the hydraulic system.
• Hand-tighten the screw with the disk (assembly lock, see illustration 11) on both sides into the setting nut
(component 1.7).
• Release the pressure fully from the hydraulic system.
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 1.11) from the venting hole (see illustrations 9
and 10).
• Drain the hydraulic oil completely from the brake.
• Dispose of the hydraulic oil as per chapter 4.12.
• Disconnect the drain and pressure oil line from the brake.
• Screw the screw plugs (component 1.11) into all pressure ports resp. venting holes (see illustrations 7 to 10).
• Remove the 4-off connection screws serving for fixing the brake half to the connection plate.
• Take out the brake half.
• Disassemble the second brake half in the same way as with the first brake half.
Please observe protection
note ISO 16016.
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4.11 Spares inventory, customer service addresses
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.
4.12 Disposal
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
Electrical components have to be treated as electrical waste.
• Hydraulic oil
Hydraulic oils have to be collected in suitable tanks and disposed of by a waste disposal company.
5
Maintenance
5.1 Replacement of brake pads

Brake pads having a balance of pad height of less than 5 mm have to be replaced by return.

Replace the brake pads in both halves of the brake simultaneously.
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 make sure that
the brake is fully secured against activating.
• Remove the screw plug (component 1.13) or the sensor (component 4) on both sides from the setting nut
(component 1.7).
• Put the opening pressure (see table 2) on the hydraulic system.
• Hand-tighten the screw with the disk (assembly lock, see illustration 11) on both sides into the brake piston
(component 1.5).
• Release the pressure fully from the hydraulic system.
Please observe protection
note ISO 16016.
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Maintenance
5.1 Replacement of brake pads
• Inspect the position of the setting nut (component 1.7) on both sides. If necessary, set it to the right dimension
(see illustration 12).
• Disassemble the pad retainers on one side (component 1.9) with both halves of brake.
• Remove the pad retraction sets (component 2) on both sides.
• Replace the brake pads that have worn off. Insert the brake pads (component 3) fully into the housing on both
sides.
• Hand-tighten the pad holders (component 1.9) on both sides by each 2-off cap screws (component 1.10) first.
Tighten the screws at the tightening torque TA = 71 Nm.
• Mount the pad retraction sets (component 2) on both sides by shifting the pressure spring (component 2.2)
onto the pin (component 2.1). Screw the pin with the pressure spring into the brake pad against a stop.

Secure the screw connection (component 2.1) on both sides on the brake pad additionally against
working loose, e. g. conglutinating with Loctite (average strength).
• Repeat chapter 4.8 Setting/re-setting of the brake
• Make sure that the brake disk can rotate freely while not touching the brake pads or the housing.

Please note chapter 4.4 Assembly of the brake.
• Before you reactivate the brake, please observe chapter 4.7 Start-up of the brakes.
5.2 Maintenance of the brake / replacement of single parts

To ensure the full braking power, both disassembly and assembly have to be performed at
the highest level of purity.
• Disassemble the brake, please observe chapter 4.10 Disassembly of the brake.
• Remove the pad retraction sets (component 2) on both sides.
• Take out the brake pads (component 3).
Illustration 13: KTR-STOP® XS-xx A-xx-xx
Please observe protection
note ISO 16016.
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Maintenance
5.2 Maintenance of the brake / replacement of single parts
• Remove the O-ring (component 1.8) on both sides.
• Put the opening pressure (see table 2) on the hydraulic system.
• Remove the screw with the disk (assembly lock, see illustration 11) on both sides from the brake piston (component 1.5).
• Release the pressure from the hydraulic system.
• Unscrew the setting nut (component 1.7) on both sides from the housing.
• Remove the set of disk springs (component 1.6) on both sides.

Make use of a tool to ensure the same arrangement of disk springs, washer and adjustment
washer(s) with re-assembly of the brake.
• Press the brake piston (component 1.5) carefully out of the housing (if necessary, use some hydraulic oil).
• Remove the gaskets (component 1.3 and 1.4) and the scraper (component 1.2).

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 new gaskets (component 1.3 and 1.4) and
scrapers (component 1.2) on both sides into the housing. For that purpose the components may be heartshaped (see illustration 15).
!

The gasket and scraper have to be installed in the right direction (see illustration
16).
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 gaskets and scrapers with hydraulic oil (see
illustration 16).
Illustration 14: Housing with single parts
Please observe protection
note ISO 16016.
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Maintenance
5.2 Maintenance of the brake / replacement of single parts
Oils and greases containing molybdenum disulphite or zinc sulphite additives must not be
used.
!
Illustration 15: Assembly of gasket and scraper
Illustration 16
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 leakages.
!
• Insert the brake piston (component 1.5) into the housing and press it against a stop.
• Shift the set of disk springs (component 1.6) into the brake piston (component 1.5). Make sure that the disks
are located on top.

Grease the disk springs properly with Molykote MoS2.
Make sure that the set of disk springs is mounted in the same arrangement as it was supplied.
If a new set of disk springs is used, the condition of supply needs to be observed in detail.
• Screw the setting nut (component 1.7) into the housing and set it to the right dimension (see illustration 12).
• Put the opening pressure (see table 2) on the hydraulic system.
• Hand-tighten the screw with the washer (assembly lock, see illustration 11) into the brake piston (component
1.5).
• Release the pressure from the hydraulic system.
• Insert a new O-ring (component 1.8) between the housing and the setting nut.
• Repeat chapters 4.2 to 4.8.
5.3 Maintenance and service
KTR-STOP® XS-xx A-xx-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, corrosion, wear of brake pads and the condition of the screw connections.

6
If you realize any irregularities, perform repairs accordingly.
Accessories - Sensor
Please observe protection
note ISO 16016.
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6.1 Technical Data „State/wear sensor“
Operation of sensor
There are two micro switches in the housing of the
sensor. The spacer pin activates the switches in two
different positions.
Illustration 17:
State/wear sensor
Table 5:
Switching status of status (switch S1) and wear switch (switch S2) depending on the activating
status of the brake.
Status of brake
Switch S1
(status signal
on/off) 1)
1 - 4 2)
2 - 3 2)
2 - 5 2)
-
0
0
1
-
1
1
0
No wear
Resetting necessary
0
1
0
0
0
1
Condition of
brake pad
Sensor not mounted
Brake not activated (unlocked)
Brake activated
(locked)
1) Status of brake
on
= brake unlocked
off
= brake locked
Switch S2
(wear signal) 1)
Illustration 18: Switch position
2) Switch position
0
= unlocked
1
= locked
Switch S2 only shows the wear status reliably when the brake is activated (locked). If the brake is not activated
(unlocked), a statement about the condition of wear cannot be given.

The wear of the brake pad is only measured if the brake is activated. If the brake is not activated, there is no signal.

„Resetting necessary“ is displayed as soon as the brake pad has worn off in that resetting
has become necessary.
!
The brake pad has to be reset as soon as the signal status „resetting necessary“ is activated.
Brake pads having a balance of pad height of less than 2 mm have to be replaced by return.
Please note chapter 5.1 Replacement of brake pads.
Fail-safe operation
A proper operating condition is only ensured if the state/wear sensor is wired properly. This provides a signal
since a switch (NO) is locked which is normally unlocked.
!
In case of damages like, for example, faulty cables, bad connections, etc. the signals need
to disappear.
Please observe protection
note ISO 16016.
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Accessories - Sensor
6.1 Technical Data „State/wear sensor“
Technical data:
Operating temperature
Max. voltage
Switching current
Protection class
Width across flats
Max. tightening torque G 1/2
Max. tightening torque M12
Length of cable
Material of cable
Dimension of cable
-40 °C to +85 °C
30 V DC/AC
100 mA
IP 65 (mounted)
24 mm
20 Nm
hand-tight
5 m, 10 m or 15 m
PUR
5 * 0.34 mm2
Illustration 19: Pin assignment of plug-in connection
6.2 Assembly / start-up
• Remove the screw plug (component 1.13) from the
setting nut (component 1.7).
• Hand-tighten the sensor (component 4) into the settting
nut first (see illustration 20).
• Tighten the sensor at the tightening torque
TA = 20 Nm.
• Provide for the electric connection according to the
plug-in connection (see illustration 19).
Illustration 20: Assembly of state/wear sensor
Please observe protection
note ISO 16016.
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