KTR-STOP® S-xx-F B-xx
Operating/Assembly instructions
KTR-N
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Edition:
44590 EN
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KTR-STOP® S-xx-F B-xx
S-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.
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
6
6
Storage, transport and packaging
6
3.1
3.2
6
6
3
4
5
6
Storage
Transport and packaging
Assembly
7
4.1 Components of the brake
4.2 Preparation of assembly
4.3 Brake pads
4.4 Assembly of the brake
4.5 Setting/resetting of the centering system
4.6 Pressure port of a brake
4.7 Pressure port of several brakes
4.8 Start-up of the brake
4.9 Setting/Resetting of the brake
4.10 Recommendation of fluids to be used
4.11 Disassembly of the brake
4.12 Spares inventory, customer service addresses
4.13 Disposal
7
10
11
11
13
14
15
16
17
18
19
19
20
Maintenance
20
5.1
5.2
5.3
20
21
24
Replacement of brake pads
Maintenance of the brake / replacement of single parts
Maintenance and service
Accessories - Sensor
6.1
6.2
25
Technical Data „State/wear sensor“
Assembly / start-up
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
1
44590 EN
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4
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
Thickness of brake disk
Pressure port
Oil bleed
towards mounting surface
Floating range on
axles
off the mounting surface
Min. diameter of brake disk ØDA
Operating temperature
Please observe protection
note ISO 16016.
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[kg]
[mm]
[mm2]
S-xx-F B-xx
Approx. 85 - 90 1)
125
28,700
[mm2]
26,800
[mm]
[μ =]
[cm2]
[cm3]
[bar]
[mm]
6
0.4
69
6.9
200
20 – 40
G 1/4
G 1/8
5
10
500
-20 to +50
[mm]
[mm]
[mm]
[°C]
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Operating/Assembly instructions
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44590 EN
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4
Technical data
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]
KTR-STOP® S-20-F B-xx
KTR-STOP® S-25-F B-xx
KTR-STOP® S-30-F B-xx
KTR-STOP® S-35-F B-xx
KTR-STOP® S-40-F B-xx
KTR-STOP® S-45-F B-xx
KTR-STOP® S-50-F B-xx
KTR-STOP® S-55-F B-xx
KTR-STOP® S-60-F B-xx
KTR-STOP® S-65-F B-xx
KTR-STOP® S-70-F B-xx
KTR-STOP® S-75-F B-xx
KTR-STOP® S-80-F B-xx
20
25
30
35
40
45
50
55
60
65
70
75
80
4.5
5.0
3.5
8.0
6.5
6.0
5.5
5.0
7.0
6.0
5.0
4.5
5.0
40
50
60
80
90
100
100
110
130
140
150
160
170
Braking torque [Nm] with
brake disk Ø [mm]
500
710
1000
2900
4600
6900
3700
5800
8700
4400
6900
10400
5100
8100
12100
5900
9200
13900
6600
10400
15600
7400
11600
17400
8100
12700
19100
8800
13900
20800
9600
15000
22600
10300
16200
24300
11100
17400
26100
11800
18500
27800
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)
Fb = Fc 2
Mb = z Fb
Fb
Fc
Mb
z
Dav
Dav
2
=
=
=
=
=
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
up to ØDA = 1000 mm
from ØDA = 1000 mm to
ØDA = 1800 mm
from ØDA = 1800 mm
DC max. = DA - 305
DC max. = DA - 295
DC max. = DA - 285
Dav = DA - 130
Dav = DA - 120
Dav = DA - 110
Please observe protection
note ISO 16016.
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Technical data
Connection dimensions of brake
Illustration 3: Connection dimensions
2
Advice
2.1 General advice
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.
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.
Please observe protection
note ISO 16016.
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Advice
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 S-xx-F B-xx described in here corresponds to the technical status at the time of printing of these
operating/assembly instructions.
3
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 applied 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.
Please observe protection
note ISO 16016.
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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 1.20) is attached to the brake in bulk.
4.1 Components of the brake
Components/component assemblies of brake – Type S-xx-F B-xx
Component/suba
ssembly
1
2
Quantity
Description
1
Caliper with components
Distance plate
Base plate with
guide pin
Centering system outside
Centering system inside
Pad retraction set movable
side
Brake pad
Pad retraction set on fixed
side
Sensor
1)
3
1
4
5
2
1
6
2
7
2
8
2
9
1 2)
1) Number depends on thickness of brake disk.
2) Optionally available
Illustration 4: Components/subassemblies of brake
Component 2: Number and position of the spacer plate
Thickness of brake
disk
20
30
40
Please observe protection
note ISO 16016.
Number of spacer plates
On top
At the bot(Pos.2a)
tom (Pos.2b)
1
1
1
-
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Assembly
4.1 Components of the brake
Subassembly 1: Caliper with components
Component
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
Quantity
Description
1
1
1
1
1
1
1
1
1
1
1
1
Brake caliper
Brake piston
Scraper
Gasket
Gasket
Set of disk springs
Setting nut
Centering pin
O-ring
Scraper
Gasket
Gasket
Screw plug VSTI (acc. to
DIN 908)
Pad retainer
Pad retainer
Cap screw
DIN EN ISO 4762 - 10.9
Drain plug (nylon)
DU bushing
Scraper
Screw plug
VSTI (acc. to DIN 908)
Drain plug
(Nylon)
1.13
4
1.14
1.15
2
2
1.16
8
1.17
1.18
1.19
2
4
4
1.20
1
1.21
1
Illustration 5: Caliper with components
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Assembly
4.1 Components of the brake
Subassembly 3: Base plate with guide pin
Component
3.1
3.2
3.3
3.4
Quantity
Description
1
2
2
Base plate
Guide pin
Disk
Cap screw
DIN EN ISO 4762 - 10.9
2
Illustration 6: Base plate with guide pin
Subassembly 4: Centering system outside
Component
Quantity
4.1
1
4.2
1
4.3
1
4.4
1
Description
Cap screw
DIN EN ISO 4762 - 10.9
Pressure spring
Hexagon nut
DIN EN ISO 4032
Drain plug
Illustration 7: Centering system outside
Subassembly 5: Centering system inside
Component
5.1
Quantity
1
5.2
1
5.3
1
Description
Pin
Hexagon nut
DIN EN ISO 4032
Drain plug
Illustration 8: Centering system inside
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Assembly
4.1 Components of the brake
Subassembly 6: Pad retraction set movable side
Component
Quantity
6.1
1
6.2
1
Description
Cap screw
DIN EN ISO 4762 - 10.9
Pressure spring
Illustration 9: Pad retraction set of brake caliper
Subassembly 8: Pad retraction set fixed side
Component
Quantity
7.1
1
7.2
7.3
1
1
Description
Cap screw
DIN EN ISO 4762 - 10.9
Pressure spring
Sealing plug
Illustration 10: Pad retraction set
4.2 Preparation of assembly
To ensure the full braking power, the preparation for assembly needs to be carefully performed.
• The connection plate for the brake as well as the brake disk have to be inspected for dimensional accuracy.
For that purpose investigate the connection dimensions, connection surfaces and tolerances as specified in
the drawing (see illustrations 1 to 3 and table 3).
• Clean and degrease the brake disk and mounting surfaces. Dirt can easily be removed by means of solvents.
The connection between connection surface and brake is defined as frictional contact. 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.
!
Please observe protection
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Assembly
4.3 Brake pads
KTR supplies brake pads free from asbestos and lead only.
If requested, we will provide you with the corresponding certificates.
The brake pads are each adapted to the application and delivered accordingly.
They can be distinguished as follows:
• organic material
• powder metal
!
!
Brake pads are highly sensitive to grease and oil which means that they cannot be cleaned.
Brake pads having such kind of dirt need to be replaced and disposed of.
We would recommend to store the brake pads in their package as long as possible to 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.
4.4 Assembly of the brake
In order to avoid any injuries please always make use of proper lifting equipment.
STOP
!
The brake is mainly selected for mounting on vertically aligned brake disks
(see illustration 3). With horizontally aligned brake disks (see illustration 1) the brake may
only be aligned upright.
M10 threads are installed in the pad retainer 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 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 19).
• Insert the brake pads (component 7) 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 1.14 and 1.15) for that purpose (chapter 5.1).
• Mount the pad retraction set on the movable side (component 8) by shifting the pressure spring (component
8.2) onto the pin (component 8.1). Screw the pin with the pressure spring into the brake pad against a stop.
• Repeat this process with the pad retraction set on the moveable side of caliper (component 6).
Secure the screw connection (component 6.1 and 8.1) on the brake pad additionally against
working loose, e. g. conglutinating with Loctite (average strength).
Please observe protection
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Assembly
4.4 Assembly of the brake
• Insert the brake in the correct position towards the
connection plate. Hand-tighten the brake via the screws
for the time being.
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 11).
• Screw the brake to the connection plate by means of 4
screws and tighten them evenly gradually at the tightening
torque specified (see table 4).
Illustration 11
Table 4: Tightening torques
Screw size
M20
Tightening torque TA [Nm]
10.9
12.9
Untreated and oiled
Greased with MoS2
Untreated and oiled
Greased with MoS2
560
420
660
490
• 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.
• Re-assemble the sealing plugs (component 7.3).
!
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.
Please observe protection
note ISO 16016.
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Assembly
4.5 Setting/resetting of the centering system
The centering systems need to be reset with initial assembly or after having replaced brake
pads or single parts, respectively. This is the only way to ensure 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 systems need to be regularly reset 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 (see illustration 12) by screwing the pin (component 5.1) either upwards or downwards.
• Secure the pin (component 5.1) via the hexagon nut (component 5.2).
• Screw the cap screws (component 4.1) into the base plate (component 3.1). The screw depth in the base
plate must be 20 mm (Only valid with a thickness of brake disk of 20 mm: screwing depth must be 30
mm).
• Seal the bores via the sealing plugs (component 4.4 and 5.3).
Illustration 12: Setting of gap
Illustration 13: 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.
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Operating/Assembly instructions
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44590 EN
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Assembly
4.6 Pressure port of a brake
• Connect the pressure oil line to one of the pressure ports of the brake (see illustration 14 and 15). 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 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 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 14 and 15). 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 regularly inspect the brake for leakages.
!
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 14: Connections of the drain lines/pressure lines
Illustration 15: 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.
Please observe protection
note ISO 16016.
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Assembly
4.7 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 16).
Please note, if several brakes are connected in a series (see illustration 17), 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 14, 16 and 17). 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 14, 16 and 17), 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 16: Pressure port of
several brakes (in parallel)
Illustration 17: 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 16) 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 14, 16 and 17). 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 regularly inspect the brake for leakages.
!
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 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.
Please observe protection
note ISO 16016.
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Operating/Assembly instructions
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44590 EN
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Assembly
4.8 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 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 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 1.13)
needs to be screwed into the venting hole (see illustrations 15 to 17).
• 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 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 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
18) from the centering pin (component 1.8).
Afterwards store the assembly lock (screw with
disk) in a safe place since it will be required
again later.
• Screw the screw plug (component 1.20) 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 1.20).
• The brake pads have to be ground in on the surface of the
brake disk to achieve the nominal coefficient of friction.
Bild 18: Assembly lock
Please observe the instructions for grinding-in according to KTR-N.
Please observe protection
note ISO 16016.
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4
Assembly
4.9 Setting/Resetting 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.
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 1.9) and the screw plug (component 1.20).
• Applying with the use of a sensor only:
Remove the sensor (component 9).
• 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
18) into the centering pin (component 1.8).
• 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 adjusting nut either
upwards or downwards.
• Applying for 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 1/2 revolution.
• Insert the O-ring (component 1.9) between the housing and the
setting nut.
Illustration 19: 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 9) according to chapter 6.2 instead of the screw plug (component 1.20).
Please observe protection
note ISO 16016.
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4
Assembly
4.10 Recommendation of fluids 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 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.
As a standard the KTR basic power packs are equipped with a 10-µm-inline filter.
In order to ensure the reliability of the system, only those oils originating from the following purity classes are
permitted:
• ISO 4406, class 18/16/13
Maintenance operations on the hydraulic system
In order to ensure a smooth operation of the overall system, the maintenance operations on the hydraulic system
(inspection of level and degree of dirt, replacing the hydraulic 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.
Please observe protection
note ISO 16016.
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4
Assembly
4.11 Disassembly of the brake
In order to avoid any personal injuries, protect the brake by means of the assembly lock.
STOP
• Remove the screw plug (component 1.20) 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 18) 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
15 to 17).
• 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 14 to 17).
• Remove the 4-off screws serving for fixing the brake to the connection plate.
• Take out the brake.
4.12 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.
Please observe protection
note ISO 16016.
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Assembly
4.13 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
STOP
!
Brake pads having a balance of pad height of less than 2 mm have to be replaced by return.
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 1.20) or the sensor (component 9) from the setting nut (component 1.7).
• Put the opening pressure (see table 2) onto the hydraulic system.
• Screw the screw with the disk (assembly lock, see illustration 17) hand-tight into the centre bolt (component
1.8).
• 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 19).
• Disassemble the pad holders on one side (component 1.14 and 1.15).
• Remove the pad retracting sets (component 6 and 8).
• Replace the brake pads that have worn off. Insert the brake pads (component 7) fully into the brake caliper or
the distance plate, respectively.
• Hand-tighten the pad holders (component 1.14 and 1.15) by each 2-off cap screws (component 1.16) for the
time being. Tighten the screws at the tightening torque TA = 302 Nm.
Please make sure that the pad holders of the housing have various heights.
Please observe protection
note ISO 16016.
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4
Maintenance
5.1 Replacement of brake pads
• Mount the pad retraction set on the movable side (component 8) by shifting the pressure spring (component
8.2) onto the pin (component 8.1). Screw the pin with the pressure spring into the brake pad against a stop.
• Repeat this process with the pad retraction set on the moveable side of caliper (component 6).
Secure the screw connection (component 6.1 and 8.1) 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 3 out of the 4 screws alternatively. Swing the brake out of its position.
Please note chapter 4.4 Assembly of the brake.
• Before you reactivate the brake, please observe chapter 4.8 Start-up of the brake.
5.2 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 4.11
Disassembly of the brake.
• Remove the pad retracting sets (component 6 and 8).
• Take out the brake pads (component 7) and the distance
plates (component 2).
• Remove the sealing plugs from the external centering
system (component 4.4). Untighten the hexagon nuts
(component 4.3) and unscrew the cap screws (component 4.1) from the base plate.
• Remove the brake caliper (component 1) from the guide
pin (component 3).
!
Inspect the components/component assemblies 2, 3 and 4 for any kind of damage; it may be necessary to replace the
components.
Afterwards remove dirt, grease and corrosion from the components.
Illustration 20: KTR-STOP® XS-xx-F B-xx
Please observe protection
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4
Maintenance
5.2 Maintenance of the brake / replacement of single parts
• Remove the O-ring (component 1.9).
• Put the opening pressure (see table 2) onto the hydraulic system.
• Remove the screw with the disk (assembly lock, see illustration 18) from the centering pin (component 1.8).
• Release the pressure from the hydraulic system.
• Unscrew the setting nut (component 1.7) from the housing.
• Remove the set of disk springs (component 1.6).
Please make use of a tool to ensure that you can provide for the same arrangement of disk
springs, disk and adjustment washer(s) with re-assembly of the brake.
• Press the brake piston (component 1.2) carefully out of the brake caliper (if necessary, use some hydraulic
oil).
• Remove the gaskets (component 1.4 and 1.5) and the scraper (component 1.3).
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.
!
!
Please observe the manufacturer’s instructions regarding the use of solvents.
Inspect the DU bushes (component 1.18),
scrapers (component 1.19) and centering
pins (component 1.8) for any kind of damage; if necessary, the components have
to be replaced. Afterwards remove dirt,
grease and corrosion from the components.
• Insert new gaskets (component 1.4 and 1.5) and
scrapers (component 1.3 and 1.19) into the housing. For
that purpose the components may be heart-shaped (see
illustration 21).
!
The gasket and scraper have to be installed in the right direction (see illustration
22).
With a new assembly 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 the scraper with hydraulic oil
(see illustration 22).
Illustration 21: Housing with single parts
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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 22: Assembly of gasket and scraper
!
Illustration 23
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 1.2) into the brake caliper and press it against a stop.
• Shift the set of disk springs (component 1.6) into the brake piston (component 1.2). Make sure that the disks
are located on top.
Grease the disk springs properly with Molykote MoS2.
Please 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 19).
• Put the opening pressure (see table 2) onto the hydraulic system.
• Hand-tighten the screw with the disk (assembly lock, see illustration 18) into the setting nut (component 1.7).
• Release the pressure from the hydraulic system.
• Insert a new O-ring (component 1.9) between the brake caliper and the setting nut.
• After having disassembled the pin of the internal centering system (component 5.1), screw the pin (component
5.1) into the brake caliper. Afterwards screw the hexagon nuts (component 5.2) onto the pin.
• Fit the pre-assembled unit carefully onto the guide pins.
Please make sure that the centering system (component 5) is not damaged.
Please observe protection
note ISO 16016.
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4
Maintenance
5.2 Maintenance of the brake / replacement of single parts
• Shift the cap screws (component 4.1) with the pressure springs (component 4.2) into the brake caliper. Screw
the hexagon nut (component 4.3) onto the cap screw (component 4.1).
• Set the gap between brake disk and brake pad to 0.5 mm (see illustration 24) by screwing the pin (component
5.1) either upwards or downwards.
• Secure the pin (component 5.1) via the hexagon nut (component 5.2).
• Screw the cap screws (component 4.1) into the base plate (component 3.1). The screw depth in the base plate
must be 20 mm (Only valid with a thickness of brake disk of 20 mm: screwing depth must be 30 mm).
• Seal the bores via the sealing plugs (component 4.4 and 5.3).
• Repeat chapters 4.2 to 4.9.
Illustration 24: Setting of gap
Illustration 25: Setting of centering system
5.3 Maintenance and service
KTR-STOP® S-xx-F 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, corrosion, wear of brake pads and the condition of the screw connections.
If you realize any irregularities, please perform repairs accordingly.
Please observe protection
note ISO 16016.
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Accessories - Sensor
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 26:
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
Status 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 27: 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 a way 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
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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 28: Pin assignment of plug-in connection
6.2 Assembly / start-up
• Remove the screw plug (component 1.20) from the
setting nut (component 1.7).
• Hand-tighten the sensor (component 9) into the settting
nut first (see illustration 29).
• Tighten the sensor at the tightening torque
TA = 20 Nm.
• Provide for the electric connection according to the
plug-in connection (see illustration 28).
Illustration 29: Assembly of state/wear sensor
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">
