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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.
KTR-STOP
Operating/Assembly instructions
KTR-STOP
Drawn:
2019-08-13 Pz/Mro
Verified:
2019-08-13 Pz
®
S-A-F B-xx
®
S-A-F B-xx
Replacing:
Replaced by:
KTR-N
44591 EN
Sheet:
1 of 24
Edition:
5
KTR-N dated 2018-12-04
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Table of Contents
Related Manuals for KTR-Group KTR-STOP S-A-F B Series
Summary of Contents for KTR-Group KTR-STOP S-A-F B Series
- Page 1 KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 1 of 24 Operating/Assembly instructions Edition: ® 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.
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Page 2: Table Of Contents
KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 2 of 24 Operating/Assembly instructions Edition: 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 Technical data Advice... -
Page 3: Technical Data
KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 3 of 24 Operating/Assembly instructions Edition: Technical data Illustration 1: Dimensi- onal drawing Table 1: Technical data S-A-F B-xx Weight [kg] Approx. 78 Width of brake pad [mm] organic 28,700 Surface of each brake pad powder 26,800 metal... - Page 4 KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 4 of 24 Operating/Assembly instructions Edition: Technical data Calculation of brake disk: Illustration 3: Assembly of brake Table 2: Calculation of brake disk from ØD = 1000 mm to up to ØD = 1000 mm from ØD = 1800 mm...
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Page 5: Advice
KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 5 of 24 Operating/Assembly instructions Edition: 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. -
Page 6: Storage, Transport And Packaging
KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 6 of 24 Operating/Assembly instructions Edition: 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 pro- tection 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. -
Page 7: Assembly
KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 7 of 24 Operating/Assembly instructions Edition: Assembly The brake is supplied in pre-assembled condition. Before assembly the brake has to be inspected for complete- ness. 4.1 Components of the brake Components/subassemblies of brake – Type S-A-F B-xx Compo- nent/comp Quantity... - Page 8 KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 8 of 24 Operating/Assembly instructions Edition: Assembly 4.1 Components of the brake Subassembly 1: Caliper with components Compo- Quantity Description nent Brake caliper (incl. piston cover) DU bushing Pad retainer Pad retainer Cap screw DIN EN ISO 4762 - 10.9 Screw plug...
- Page 9 KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 9 of 24 Operating/Assembly instructions Edition: Assembly 4.1 Components of the brake Subassembly 4: Centering system outside Compo- Quantity Description nent Cap screw DIN EN ISO 4762 - 10.9 Pressure spring Hexagon nut DIN EN ISO 4032 Drain plug Illustration 8: Centering system outside...
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Page 10: Preparation Of Assembly
KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 10 of 24 Operating/Assembly instructions Edition: Assembly 4.1 Components of the brake Subassembly 8: Pad retraction set fixed side Compo- Quantity Description nent Cap screw DIN EN ISO 4762 - 10.9 Pressure spring Sealing plug Illustration 11: Pad retraction set 4.2 Preparation of assembly... -
Page 11: Brake Pads
KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 11 of 24 Operating/Assembly instructions Edition: 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: •... - Page 12 KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 12 of 24 Operating/Assembly instructions Edition: Assembly 4.4 Assembly of the brake • Insert the brake in the correct position towards the con- nection plate. Hand-tighten the brake via the screws for the time being.
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Page 13: Setting/Resetting Of The Centering System
KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 13 of 24 Operating/Assembly instructions Edition: 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. -
Page 14: Pressure Port Of A Brake
KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 14 of 24 Operating/Assembly instructions Edition: 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. -
Page 15: Pressure Port Of Several Brakes
KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 15 of 24 Operating/Assembly instructions Edition: 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 ef- fect of all following brakes may become effective slightly delayed. -
Page 16: Start-Up Of The Brake
KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 16 of 24 Operating/Assembly instructions Edition: Assembly 4.8 Start-up of the brake Before start-up and after each operation on the brake the hydraulic system has to be gener- ally 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. -
Page 17: Disassembly Of The Brake
KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 17 of 24 Operating/Assembly instructions Edition: 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. -
Page 18: Disposal
KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 18 of 24 Operating/Assembly instructions Edition: 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. •... -
Page 19: Maintenance Of The Brake / Replacement Of Single Parts
KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 19 of 24 Operating/Assembly instructions Edition: 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). •... - Page 20 KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 20 of 24 Operating/Assembly instructions Edition: 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.
- Page 21 KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 21 of 24 Operating/Assembly instructions Edition: 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.
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Page 22: Maintenance And Service
KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 22 of 24 Operating/Assembly instructions Edition: 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). -
Page 23: Accessories - Sensor
KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 23 of 24 Operating/Assembly instructions Edition: 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. -
Page 24: Assembly / Start-Up
KTR-N 44591 EN ® KTR-STOP S-A-F B-xx Sheet: 24 of 24 Operating/Assembly instructions Edition: 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).
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