KTR-STOP® S-A-F B-xx
Operating/Assembly instructions
KTR-N
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44591 EN
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KTR-STOP® S-A-F B-xx
S-A-F B-xx is a brake actuated hydraulically in a floating caliper design serving to
generate a brake force on a brake disk in order to decelerate a machine's
movement or stop it, respectively, or keep it at standstill.
Please observe protection
note ISO 16016.
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The KTR brake system was designed to operate as a service brake/emergency stop brake on rotating
brake disks. For any other applications please consult with KTR.
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
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 Recommendation of fluids to be used
4.10 Disassembly of the brake
4.11 Spares inventory, customer service addresses
4.12 Disposal
7
10
11
11
13
14
15
16
16
17
17
18
Maintenance
18
5.1
5.2
5.3
18
19
22
Replacement of brake pads
Maintenance of the brake / replacement of single parts
Maintenance and service
Accessories - Sensor
6.1
6.2
23
Technical Data „State/wear sensor“
Assembly / start-up
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Operating/Assembly instructions
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44591 EN
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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 3)
Rated coefficient of friction 4)
Total brake piston surface - complete brake
Volume for each brake caliper with 1 mm stroke
Max. operating pressure
Width of brake disk
Pressure port
Oil bleed
towards mounting surface
Floating range on
axles
away from mounting surface
Min. diameter of brake disk ØDA
Operating temperature
[kg]
[mm]
[mm2]
S-A-F B-xx
Approx. 78 1)
125
28,700
[mm2]
26,800
[mm]
[μ =]
[cm2]
[cm3]
[bar]
[mm]
6
0.4
44.2
4.2
125
20 – 40
G 1/4
G 1/8
5
10
500
-20 to +50
[mm]
[mm]
[mm]
[°C]
3) The permissible wear reduces with deviating thickness of brake disk.
4) The friction coefficient each depends on the application or material of the brake pad; please consult with KTR.
Fb = Fc 2
Mb = z Fb
Fb
Fc
Mb
z
DA
0.125
=
=
=
=
=
=
D A − 0,125
2
Braking power [kN]
Clamping force [kN]
Braking torque [kNm]
Number of brakes
Outside diameter of brake disk [m]
Width of brake pad [m]
Illustration 2: Diagramme – KTR-STOP® S-A-F
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Technical data
Calculation of brake disk:
Illustration 3: Assembly of brake
Table 2: 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
Connection dimensions of brake
Illustration 4: Connection dimensions
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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.
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-A-F B-xx described in here corresponds to the state of the art 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 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 quantity and kind of transport. Unless otherwise contractually
agreed, packaging will follow the in-house packaging specifications of KTR.
Please observe protection
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Assembly
The brake is supplied in pre-assembled condition. Before assembly the brake has to be inspected for completeness.
4.1 Components of the brake
Components/subassemblies of brake – Type S-A-F B-xx
Component/comp
onent
assembly
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) Quantity depends on thickness of brake disk.
2) Optionally available
Illustration 5: Components/subassemblies of brake
Component 2: Quantity and position of the spacer plate
Thickness of
brake disk
20
30
40
Quantity of spacer plates
On top
At the bottom
(Pos.2a)
(Pos.2b)
1
1
1
-
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Assembly
4.1 Components of the brake
Subassembly 1: Caliper with components
Component
Quantity
1.1
1
1.2
1.3
1.4
4
2
2
1.5
8
1.6
4
1.7
1.8
1.9
1.10
1
1
1
1
1.11
1
Description
Brake caliper
(incl. piston cover)
DU bushing
Pad retainer
Pad retainer
Cap screw
DIN EN ISO 4762 - 10.9
Screw plug
VSTI (acc. to DIN 908)
Drain plug
Brake piston
Scraper
Gasket
Screw plug
VSTI (acc. to DIN 908)
Illustration 6: Caliper with components
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 7: Base plate with guide pin
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Assembly
4.1 Components of the brake
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 8: 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 9: Centering system inside
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 10: Pad retraction set of brake caliper
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Assembly
4.1 Components of the brake
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 11: 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 4 and table 2).
• Clean and degrease the brake disk and mounting surfaces. Dirt can easily be removed by means of solvents.
The connection between connection 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
note ISO 16016.
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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 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 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 4). 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.
• Insert the brake pads (component 7) fully into the brake caliper.
• Applying for the movable side only:
Push back the brake pad and brake piston manually.
!
Please make sure that at least one screw plug (component 1.6) is removed when moving
back the brake piston. Afterwards re-assemble the screw plug.
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 fixed side of caliper (component 6).
Please observe protection
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Assembly
4.4 Assembly of the brake
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).
• 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 12).
• Screw the brake to the connection plate by means of 4
screws and tighten them evenly gradually at the tightening
torque specified (see table 3).
Illustration 12
Table 3: 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 2 needs to be observed.
Please make sure that the tolerances of the brake disk do not exceed the figures specified
in illustration 4.
• Optional component:
Assemble the sensor (component 9) according to chapter 6.2.
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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 the requested value 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 13: Setting of centering system
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Operating/Assembly instructions
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44591 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
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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 15, 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
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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).
• Put some pressure on the hydraulic system. This will allow the brake pads to fit onto the brake disk.
• 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.
Please observe the instructions for grinding-in according to KTR-N.
4.9 Recommendation of fluids to be used
!
You may only use mineral hydraulic fluids meeting the specifications of DIN 51524. KTR
recommends those fluids corresponding to DIN 51524-3.
KTR recommends the following fluids (other manufacturers may be selected):
Manufacturer
Mineral oil
Castrol
Shell
Mobil
Hydro Texaco
Valvoline
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 TX32
Tellus TX46
DTE 13M
DTE 15M
Rando HDZ32
Rando HDZ46
Ultramax HVLP32
Ultramax HVLP46
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 Artic
Tellus TX68
DTE 16M
Rando Ashless 8401
Rando HDZ68
Ultramax HVLP68
The permissible operating temperatures of brake components from - 20 °C to + 60 °C (- 4 °F
to + 140 °F) have to be observed. For deviating operating temperatures please consult with
KTR.
Viscosity
We would recommend a viscosity range from 20 to 220 mm2/s (cSt) of the hydraulic fluid with operating temperature. The viscosity during starting should not exceed 500 mm2/s and the viscosity during operation should not fall
below 12 mm2/s.
Filtration
When filling and re-filling the hydraulic system and replacing the hydraulic fluid, the oil needs to be filtered. For
that purpose use an offline filter or a respective fill unit. In addition we would recommend to use an inline filter.
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Assembly
4.9 Recommendation of fluids to be used
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 fluid 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 fluid.
!
Adverse reactions may be generated by mixing different fluids or fluids of various manufacturers.
Please contact the manufacturer of mineral oils if you intend to replace the hydraulic fluid.
4.10 Disassembly of the brake
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.
If a sensor is used (component 9) it has to be removed before the brake is disassembled.
• 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.
• Remove the 4-off screws serving for fixing the brake to the connection plate.
• Take out the brake.
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.
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-01-11 Ka/Wie
2022-01-28 Ka
Replacing:
Replaced by:
KTR-N dated 2019-08-13
KTR-STOP® S-A-F B-xx
Operating/Assembly instructions
4
KTR-N
Sheet:
Edition:
44591 EN
18 of 24
6
Assembly
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
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.
• 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.
• Applying for the movable side only:
Push back the brake pad and brake piston manually.
!
Please make sure that at least one screw plug (component 1.6) is removed when moving
back the brake piston. Afterwards re-assemble the screw plug.
• Hand-tighten the pad holders (component 1.14 and 1.15) by each 2-off cap screws (component 1.11) 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.
• 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 fixed side of caliper (component 6).
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-01-11 Ka/Wie
2022-01-28 Ka
Replacing:
Replaced by:
KTR-N dated 2019-08-13
KTR-STOP® S-A-F B-xx
Operating/Assembly instructions
5
KTR-N
Sheet:
Edition:
44591 EN
19 of 24
6
Maintenance
5.1 Replacement of brake pads
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 18: KTR-STOP® S-A-F B-xx
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-01-11 Ka/Wie
2022-01-28 Ka
Replacing:
Replaced by:
KTR-N dated 2019-08-13
KTR-STOP® S-A-F B-xx
Operating/Assembly instructions
5
KTR-N
Sheet:
Edition:
44591 EN
20 of 24
6
Maintenance
5.2 Maintenance of the brake / replacement of single parts
• Connect the hydraulics to a pressure port (see illustration 14) of the caliper and make sure that all other
pressure ports are locked by screw plugs.
• Press the brake piston (component 1.8) carefully out of the brake caliper (if necessary, use some hydraulic
oil).
• Remove the gasket (component 1.10) and the scraper (component 1.9).
When removing the gaskets and scrapers please make sure that the keyways in the caliper
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 1.10) and scrapers
(component 1.9) into the caliper. For that purpose the
components may be heart-shaped (see illustration 20).
!
Illustration 19: Caliper with single parts
The gasket and scraper have to be installed in the right direction (see illustration 21).
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 21).
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-01-11 Ka/Wie
2022-01-28 Ka
Replacing:
Replaced by:
KTR-N dated 2019-08-13
KTR-STOP® S-A-F B-xx
Operating/Assembly instructions
5
KTR-N
Sheet:
Edition:
44591 EN
21 of 24
6
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 20: Assembly of gasket and scraper
!
Illustration 21
Inspect the surfaces of the brake piston and the hole of the piston cover 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 1.8) into the caliper and press it against a stop.
• Depending on the thickness of brake disk:
Fit the spacer plate (component 2). Please conclude position and number of spacer plate from the customer
drawing.
• 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.
Drawn:
Verified:
2022-01-11 Ka/Wie
2022-01-28 Ka
Replacing:
Replaced by:
KTR-N dated 2019-08-13
KTR-STOP® S-A-F B-xx
Operating/Assembly instructions
5
KTR-N
Sheet:
Edition:
44591 EN
22 of 24
6
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).
• 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 4.8.
Illustration 22: Setting of centering system
5.3 Maintenance and service
KTR-STOP® S-A-F B-xx is a low-maintenance brake. We recommend to perform a visual inspection and a functional test 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.
Drawn:
Verified:
2022-01-11 Ka/Wie
2022-01-28 Ka
Replacing:
Replaced by:
KTR-N dated 2019-08-13
KTR-STOP® S-A-F B-xx
Operating/Assembly instructions
6
KTR-N
Sheet:
Edition:
44591 EN
23 of 24
6
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 23:
State/wear sensor
Table 4:
Switching status of pre- (switch S1) and end wear switch (switch S2) depending on the activating status of the brake.
Status of brake
Status of brake
pad
Switch S1
1 - 4 1)
-
0
0
1
-
1
1
0
No wear
Pre-wear
End wear
1
0
0
1
1
0
0
0
1
Sensor not
mounted
Brake not activated (unlocked)
Brake activated
(locked)
1) Condition of brake
on
= no wear
off
= pre-wear
Switch S2
2 - 3 2)
2 - 5 2)
Illustration 24: Switch position
2) Switch position
0
= unlocked
1
= locked
The sensor 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.
"Pre-wear" is indicated as soon as the brake pad has worn off so that the brake pads need
to be replaced.
!
The brake pad needs to be replaced immediately if the signal indicating the status „end
wear“ is displayed. Please note chapter 5.1 Replacement of brake pads.
Fail-safe operation
A proper operation 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.
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
Please observe protection
note ISO 16016.
Drawn:
Verified:
- 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
2022-01-11 Ka/Wie
2022-01-28 Ka
Illustration 25: Pin assignment of plug-in connection
Replacing:
Replaced by:
KTR-N dated 2019-08-13
KTR-STOP® S-A-F B-xx
Operating/Assembly instructions
6
KTR-N
Sheet:
Edition:
44591 EN
24 of 24
6
Accessories - Sensor
6.2 Assembly / start-up
• Remove the screw plug (component 1.20) from the
setting nut (component 1.7).
• Screw the sensor (component 9) hand-tight into the
brake for the time being (see illustration 26).
• Tighten the sensor at the tightening torque
TA = 20 Nm.
• Provide for the electric connection according to the
plug-in connection (see illustration 25).
Illustration 26: Assembly of state/wear sensor
Please observe protection
note ISO 16016.
Drawn:
Verified:
2022-01-11 Ka/Wie
2022-01-28 Ka
Replacing:
Replaced by:
KTR-N dated 2019-08-13
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