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KTR-STOP

®

 XS-xx A-xx-xx 

Operating/Assembly instructions 

KTR-N 
Sheet: 
Edition: 

45126 EN 
21 of 22 

 

Please observe protection 

note ISO 16016. 

Drawn: 

2020-04-09 Shg/Wie 

Replacing: 

--- 

Verified: 

2020-08-11 Shg 

Replaced by: 

 

 

 

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

 

Condition of 

brake pad

 

Switch S1 

Switch S2 

 

Illustration 18: Switch position 

(status signal 

on/off) 

1)

 

(wear signal) 

1)

 

1 - 4 

2)

 

2 - 3 

2)

 

2 - 5 

2)

 

Sensor not moun-

ted 

Brake not acti-

vated (unlocked) 

Brake activated 

(locked) 

No wear 

Resetting neces-

sary 

 

1)  Status of brake 

on 

=  brake unlocked 

off 

=  brake locked 

2)  Switch position 

=  unlocked 

=  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 acti-
vated, 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 acti-
vated. 
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. 

 
 
 
 
 
 
 
 

6.1 

Technical Data „State/wear sensor“ 

Summary of Contents for KTR-STOP XS A Series

Page 1: ...note ISO 16016 Drawn 2020 04 09 Shg Wie Replacing Verified 2020 08 11 Shg Replaced by KTR STOP XS xx A xx xx XS xx A xx xx is a spring actuated brake in a fixed calliper design serving to ge nerate a...

Page 2: ...ort and packaging 6 3 1 Storage 6 3 2 Transport and packaging 6 4 Assembly 6 4 1 Components of the brake 7 4 2 Preparation of assembly 8 4 3 Brake pads 8 4 4 Assembly of the brake 9 4 5 Pressure port...

Page 3: ...l data XS xx A xx xx Weight kg Approx 20 Width of brake pad mm 70 Surface of each brake pad organic mm2 8 000 powder metal mm2 5 800 Max wear of each brake pad mm 5 Rated coefficient of friction 2 0 4...

Page 4: ...R STOP XS 8 A xx xx 8 16 5 120 730 1510 2280 KTR STOP XS 9 A xx xx 9 12 0 130 820 1700 2570 KTR STOP XS 10 A xx xx 10 10 0 140 910 1890 2850 KTR STOP XS 11 A xx xx 11 8 5 150 1000 2080 3140 KTR STOP X...

Page 5: ...wing safety indica tions 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 Sec...

Page 6: ...de 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...

Page 7: ...traction set 3 2 Brake pad 4 2 1 Sensor 1 Optionally available Illustration 3 Components subassemblies of brake Subassembly 1 Housing with components Compo nent Quantity Description Illustration 4 Hou...

Page 8: ...connection surface and brake is defined as frictional connection Any residues of oil dirt and corrosion protection reduce the coefficient of friction As a re sult the operation of the brake and the fu...

Page 9: ...mponent 1 7 If necessary set it to the right dimension see illustrati on 12 Insert the brake pads component 3 fully into the housing If you want to insert brake pads after having assembled the brake i...

Page 10: ...not exceed the figures specified in illust ration 2 Connect the pressure oil line to one of the pressure ports of the brake see illustration 7 and 8 For that pur pose remove the screw plug beforehand...

Page 11: ...parent 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...

Page 12: ...ts may be damaged and the operation of the brake is no longer ensured Illustration 9 Pressure port of several brakes in parallel Illustration 10 Pressure port of several brakes in a series The pressur...

Page 13: ...id in the hydraulic system during and after the venting pro cess 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 hy...

Page 14: ...nt of friction Please observe the instructions for grinding in according to KTR N The brake needs to be set with the initial assembly or after having replaced the brake pads or single parts respective...

Page 15: ...omponent 1 13 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 ma...

Page 16: ...njuries protect the brake on both sides by means of the as sembly 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 p...

Page 17: ...sidual 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 Brake...

Page 18: ...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 side...

Page 19: ...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 hav...

Page 20: ...lykote MoS2 Make sure that the set of disk springs is mounted in the same arrangement as it was supp lied If a new set of disk springs is used the condition of supply needs to be observed in detail Sc...

Page 21: ...f brake locked 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 condi...

Page 22: ...tightening torque M12 hand tight Length of cable 5 m 10 m or 15 m Material of cable PUR Dimension of cable 5 0 34 mm2 Illustration 19 Pin assignment of plug in connection Remove the screw plug compon...

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