KTR-Group KTR-STOP TB Thuster Manual

KTR-STOP® TB Thruster
acc. to DIN 15430
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44414 EN
1 of 17
4
Please observe protection
note ISO 16016.
Drawn:
2020-11-02 Shg/Mro
Replacing:
KTR-N dated 2020-04-08
Verified:
2020-11-02 Shg
Replaced by:
KTR-STOP®TB
Thruster acc. to DIN 15430
KTR-STOP®TB Thruster
The KTR-STOP®TB thruster acc. to DIN 15430 is intended for use in general
industrial plants serving mainly as a thruster, as an example, in drum and disk
brake systems.

KTR-STOP® TB Thruster
acc. to DIN 15430
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44414 EN
2 of 17
4
Please observe protection
note ISO 16016.
Drawn:
2020-11-02 Shg/Mro
Replacing:
KTR-N dated 2020-04-08
Verified:
2020-11-02 Shg
Replaced by:
1Technical data 3
2Advice 5
2.1 General advice 5
2.2 Safety and advice symbols 5
2.3 General hazard warnings 5
2.4 Intended use 6
2.5 Special safety instructions 7
3Storage, transport and packaging 7
3.1 Storage 7
3.2 Transport and packaging 7
4KTR-STOP®TB Thruster acc. to DIN 15430 8
4.1 Components of the thruster 8
4.2 Operating description of thruster acc. to DIN 15430 8
5Mechanical version 9
5.1 Installation position 9
5.2 Unit temperature and ambient temperatures 9
6Electrical version 10
6.1 Connections 10
6.2 Operating voltage 10
6.3 Operation mode 10
7Special versions 10
7.1 Globe and/or lowering valve 10
7.2 Rapid lowering control 10
7.3 Limit switch 11
7.4 Standstill heating 11
8Hydraulic liquid and lubricants as well as operating behaviour 12
8.1 Inspection of liquid level 12
8.2Refilling 13
8.3 Operating behaviour depending on ambient temperature 13
9Installation 13
9.1 Assembly 13
9.2 Electrical connection 14
10 Initial start-up 14
11 Disposal 15
12 Maintenance 16
13 Trouble shooting 17
Table of contents

KTR-STOP® TB Thruster
acc. to DIN 15430
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44414 EN
3 of 17
4
Please observe protection
note ISO 16016.
Drawn:
2020-11-02 Shg/Mro
Replacing:
KTR-N dated 2020-04-08
Verified:
2020-11-02 Shg
Replaced by:
Ed 230/50 –Ed 800/60
Illustration 1: KTR-STOP®TB Thruster 800/60
KTR-STOP®TB Thruster
Size
Dimensions [mm]
s
b1
b2
b3
b4
b5
b6
d12)
d21)
h1
h2
h3
h4
h5
Ed 230/50
50
40
80
20
160
80
200
16
16
286
20
16
26
12
Ed 300/50
50
40
80
25
160
80
197
16
16
370
18
16
34
15
Ed 500/60
60
60
120
30
195
97
254
20
20
435
23
22
36
18
Ed 800/60
60
60
120
30
195
97
254
20
20
450
23
22
36
18
1) Tolerance: +0.1
2) Tolerance: +0.15/+0.25
1 Technical data

KTR-STOP® TB Thruster
acc. to DIN 15430
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44414 EN
4 of 17
4
Please observe protection
note ISO 16016.
Drawn:
2020-11-02 Shg/Mro
Replacing:
KTR-N dated 2020-04-08
Verified:
2020-11-02 Shg
Replaced by:
Ed 1250/60 –Ed4500/120
Illustration 2: KTR-STOP®TB Thruster 3000/120
KTR-STOP®TB Thruster
Size
Dimensions [mm]
s
b1
b2
b3
b4
b5
b6
d12)
d21)
h1
h2
h3
h4
h5
h6
Ed 1250/60
60
40
90
40
240
112
260
25
25
645
35
25
117
25
38
Ed 1250/120
120
40
90
40
240
112
260
25
25
705
35
25
177
25
38
Ed 2000/60
60
40
90
40
240
112
260
25
25
645
35
25
117
25
38
Ed 2000/120
120
40
90
40
240
112
260
25
25
705
35
25
177
25
38
Ed 3000/60
60
40
90
40
240
112
260
25
25
645
35
25
117
25
38
Ed 3000/120
120
40
90
40
240
112
260
25
25
705
35
25
177
25
38
Ed 4000/60
60
40
90
40
240
112
260
25
25
645
35
25
117
25
38
Ed 4000/120
120
40
90
40
240
112
260
25
25
705
35
25
177
25
38
Ed 4500/60
60
40
90
40
240
112
260
25
25
645
35
25
117
25
38
Ed 4500/120
120
40
90
40
240
112
260
25
25
705
35
25
177
25
38
1) Tolerance: +0.1
2) Tolerance: +0.15/+0.25
1 Technical data

KTR-STOP® TB Thruster
acc. to DIN 15430
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44414 EN
5 of 17
4
Please observe protection
note ISO 16016.
Drawn:
2020-11-02 Shg/Mro
Replacing:
KTR-N dated 2020-04-08
Verified:
2020-11-02 Shg
Replaced by:
Table 1: Technical data
Type
Power
[N]
Stroke
[mm]
Rated
frequency [Hz]
Rated voltage
[V]
Rated current
[A]
Rated power
[W]
Weight
[kg]
Ed 230/50
230
50
50
230/400
0.9 / 0.6
165
10
Ed 300/50
300
50
50
230/400
1.0 / 0.7
200
14
Ed 500/60
500
60
50
230/400
1.0 / 0.7
210
23
Ed 800/60
800
60
50
230/400
2.1 / 1.2
330
24
Ed 1250/60
1250
60
50
230/400
2.1 / 1.2
330
39
Ed 1850/60
1850
60
50
230/400
2.2 / 1.3
450
39
Ed 2000/60
2000
60
50
230/400
2.2 / 1.3
450
39
Ed 3000/60
3000
60
50
230/400
2.4 / 1.4
550
40
Ed 4000/60
4000
60
50
230/400
2.6 / 1.7
650
40
Ed 4500/60
4500
60
50
230/400
2.6 / 1.7
650
40
Ed 1250/120
1250
120
50
230/400
2.1 / 1.2
330
39
Ed 2000/120
2000
120
50
230/400
2.2 / 1.3
450
39
Ed 3000/120
3000
120
50
230/400
2.4 / 1.4
550
40
Ed 4000/120
4000
120
50
230/400
2.6 / 1.7
650
40
Ed 4500/120
4500
120
50
230/400
2.6 / 1.7
650
40
Ed 1850/160
1850
155
50
230/400
2.2 / 1.3
450
40
Please read carefully through these operating/assembly instructions before you start up the thruster.
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.
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.
STOP
Assembly and installation operations may only be performed by skilled staff knowing the
respective technical provisions and accident prevention regulations!
STOP
In case of power failure or when switching off thrusters already installed there is the risk of
squeezing caused by components of the plant, since the lifting rod retracts automatically
due to internal or external brake spring or weight load by force. Danger of squeezing!
1 Technical data
2 Advice
2.1 General advice
2.2 Safety and advice symbols
2.3 General hazard warnings

KTR-STOP® TB Thruster
acc. to DIN 15430
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44414 EN
6 of 17
4
Please observe protection
note ISO 16016.
Drawn:
2020-11-02 Shg/Mro
Replacing:
KTR-N dated 2020-04-08
Verified:
2020-11-02 Shg
Replaced by:
!
When handling the thruster the lifting rod must be protected; it must neiter be damaged nor
subjected to any shear force. Dirt must be avoided as well. As an example, the piston rod
seal may be damaged by colour or splashes.
STOP
With assembly, operation and maintenance of the thruster 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 thruster have to be performed taking into account "safety first".
•Please make sure to switch off the power pack before you perform your work on the thruster.
•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 thruster as long as it is in operation.
•Please secure the thruster against accidental contact. Please provide for the necessary protection devices.
Thrusters are supplied to customers reliably. Unauthorized modifications, mainly those which affect the
operational safety, are not permitted. Those modifications are as follows:
•Unscrewing of pins and screw connections
•Removal of additional equipment (e.g. limit switch, protective equipment etc.)
•Treatment through painting, varnish (lacquer) lubricants, preserving agents in assembled condition
•Metal removing, shape-modifying or mechanical treatment of thruster elements
•Mounting of additional elements which may affect one function
•The machine must be closed down as soon as any changes on the thruster are noted during operation, e.
g. different operating noise.
You may only assemble, operate and maintain the thruster if you
•have carefully read through the operating/assembly instructions and understood them
•are technically qualified and specifically trained
•are authorized by your company
The thruster may only be used in accordance with the technical data (see chapter 1). Unauthorized modifications
on the thruster 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 thruster acc. to DIN 15430 described in here corresponds to the technical status at the time of printing of
these operating/assembly instructions.
2 Advice
2.3 General hazard warnings
2.4 Intended use

KTR-STOP® TB Thruster
acc. to DIN 15430
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44414 EN
7 of 17
4
Please observe protection
note ISO 16016.
Drawn:
2020-11-02 Shg/Mro
Replacing:
KTR-N dated 2020-04-08
Verified:
2020-11-02 Shg
Replaced by:
Please pay attention to the following safety instructions before mounting and start-up of the thruster:
1. The thruster may solely be used in accordance with the application and mode of mounting specified
hereafter in the order or order confirmation.
2. Before assembly and initial start-up the user has to check if the entire thruster unit is in perfect
condition.
3. If the mounting dimensions specified cannot be adhered to, please consult with KTR before assembly.
4. The limit switches on the thruster are set by the manufacturing company and their function has to be
checked before delivery. The setting of the limit switches by the manufacturer must not be modified
without prior agreement by the manufacturer.
5. Make sure to keep the operation area free from any obstacles.
!
Leakages endanger the perfect or general operation of the thruster. Find out the reason and
take the necessary actions for repair. Close down the entire unit, if necessary.
Upon receipt of delivery inspect the consignment for completeness and potential transport damage.
Any missing components and damages should be announced to the manufacturer or sender of the
goods by return.
The thrusters can be stored in horizontal or upright position. During storage they should be protected
against weather effects, though they are generally intended for outside use. With a longer storage
period please consider that the seals may lose their elasticity which may affect their operation.
!
In order to avoid any injuries and any kind of damage please always make use of proper
transport and lifting equipment.
The thruster 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.
2 Advice
2.5 Special safety instructions
3 Storage, transport and packaging
3.1 Storage
3.2 Transport and packaging

KTR-STOP® TB Thruster
acc. to DIN 15430
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44414 EN
8 of 17
4
Please observe protection
note ISO 16016.
Drawn:
2020-11-02 Shg/Mro
Replacing:
KTR-N dated 2020-04-08
Verified:
2020-11-02 Shg
Replaced by:
The electrohydraulic thruster (Ed) described in the illustration below corresponds to DIN15430 with
regard to release force, stroke, fastening and general dimensions.
Illustration 3: Electrohydraulic thruster
Component/
subassembly
Quantity
Description
1
1
Fork-type base
2
1
Electric motor
3
1
Terminal box
4
1
Pump wheel
5
1
Tank
6
1
Housing
7
1
Piston
8
1
Piston rod
9
1
Oil filler hole
10
1
Piston rod head
S
1
Lowering valve
H
1
Globe valve
Electrohydraulic thrusters are compact systems sealed externally that mainly consist of an electric
motor and a hydraulic unit. When turned on the electric motor (component 2) in the lower section of
the housing is driving the pump wheel (component 4) of the hydraulic pump on top. The
hydrodynamic pressure generated takes effect on a piston (component 7) extending the piston rod
(component 8) to the end-of-stroke position.
4 KTR-STOP®TB Thruster acc. to DIN 15430
4.1 Components of the thruster
4.2 Operating description of thruster acc. to DIN 15430

KTR-STOP® TB Thruster
acc. to DIN 15430
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44414 EN
9 of 17
4
Please observe protection
note ISO 16016.
Drawn:
2020-11-02 Shg/Mro
Replacing:
KTR-N dated 2020-04-08
Verified:
2020-11-02 Shg
Replaced by:
When switching off the current or in the event of power failure the pump stops pumping and the
piston rod returns into its original position.
If used as a brake thruster either the brake spring (c-spring) installed in the thruster or an external
force such as a braked weight or brake spring support the return stroke. Please consider with the
application that the usable lifting force is defined by the difference of the hydrodynamic force on the
piston rod generated in the thruster and the counteracting brake force.
The lifting and lowering times depend on the load and the temperature-related viscosity of the
hydraulic oil. They can be set with devices having an integrated lowering or global valve.
If the standard lowering time of the lifting piston is not sufficient, the standard lowering time can be
reduced by parallel operation of three capacitors. This arrangement of capacitors reduces the
deceleration time when turning off the motor resulting in particularly quick reduction of the oil
pressure. In this case the thruster must be triggered by a separate contactor.
The hydraulic unit of the tank (component 5) is located in a closed housing (component 6). The oil
level can be inspected and filled up externally through the oil filler hole (component 9).
Electrohydraulic thrusters are supplied ready for assembly and painted and are provided with oil
filling. They have to be fastened in the bores of the fork-type base (component 1) and the piston rod
head (component 10) via pins.
The electrical connection is made in the terminal box (component 3). Devices from type 1250 to
4500 have a dust cover on top of the piston rod serving as additional protection against dirt and
damage.
As described above, the thruster comprises a three-phase asynchronous motor, a closed hydraulic
system and a work cylinder with piston and lifting rod in a housing.
Mounting can be made in upright position (piston rod faces upward) or with sizes 50 and 60 mm in
horizontal position (terminal box and tank face upward) and in any intermediate position. Types with
a stroke of 120 mm can only be installed vertically. The fork-type base (component 1) along with the
terminal box can be turned by 90° to the right or left (please specify in your order), the piston rod is
turnable.
STOP
The surface temperature can rise to more than 100 °C.
Danger of burning!
The operation can be performed with ambient temperatures from -20 °C to +50 °C.
For any other temperature conditions please consult with KTR.
4 KTR-STOP®TB Thruster acc. to DIN 15430
4.2 Operating description of thruster acc. to DIN 15430
5 Mechanical version
5.1 Installation position
5.2 Unit temperature and ambient temperatures

KTR-STOP® TB Thruster
acc. to DIN 15430
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44414 EN
10 of 17
4
Please observe protection
note ISO 16016.
Drawn:
2020-11-02 Shg/Mro
Replacing:
KTR-N dated 2020-04-08
Verified:
2020-11-02 Shg
Replaced by:
Electrohydraulic thrusters are driven by a three-phase motor (component 2). All units are protected
according to IP 66 (DIN EN 60529 (VDE 0470-1)). The motor winding is insulated for use in the
tropics, insulation
class F.
All types have a terminal box (component 3) with a six-pole terminal board (nine-pole as a special
type), lead connection M4, protective conductor terminal M5 and a waterproof cable gland M25x1.5
on the right. The motors are connected via star connection (Y).
The standard voltage is for example:
•400 V, 50 Hz, 3~
•460 V, 60 Hz, 3~
•500 V, 50 Hz, 3~
•690 V, 50 Hz, 3~.
Different voltage and frequencies are available on request.
The units are suitable for continuous operation S1 (100 %) and intermittent duty S3 (60 % ED) with
up to 2000 switches per hour. Deviations of the operating voltage by a maximum of ±5 % do not
have any effect on the performance of the units.
A supplement will be charged for all thrusters with special equipment:
The service life of the units can be extended by installing a globe or lowering valve The valves are
installed over the terminal box in the hydraulic space and must be set externally. The positioning
times can be extended twentyfold at the minimun, setting is made continuously- see chapter 10.
A parallel connection of three capacitors allows to reduce the standard lowering time. The
arrangement of capacitors reduces the deceleration time when turning off the motor so that the oil
pressure decreased particularly fast. In this case the thruster must be controlled by a separate
contactor.
6 Electrical version
6.1 Connections
6.2 Operating voltage
6.3 Operation mode
7 Special versions
7.1 Globe and/or lowering valve
7.2 Rapid lowering control

KTR-STOP® TB Thruster
acc. to DIN 15430
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44414 EN
11 of 17
4
Please observe protection
note ISO 16016.
Drawn:
2020-11-02 Shg/Mro
Replacing:
KTR-N dated 2020-04-08
Verified:
2020-11-02 Shg
Replaced by:
For indicating the operating position of the piston rod the thrusters can be equipped with mechanical
or inductive limit switches on request.
Temperature range
Operating liquid
Technical statement
-45 °C to +50 °C
Castrol Aero HF 585 B
If the devices are in cold condition lifting times
may extend up to four times the lifting times
specified with minus temperature range. The
lowering times remain unchanged.
below -25°C 1)
special low-temperature
oil
1) With ambient temperatures below -20°C the statements for vertical operating position apply.
The thrusters can be provided with standstill heating. It consists of heating tapes installed in the
winding serving to heat a motor with low ambient temperatures.
The standstill heating must be activated with ambient temperatures below -20°C. It must be active while
the thruster is turned off. With the motor turned on the heating must be deactivated.
Electrical data
U1
V1
W1
L N
gnge
U1
U2
W2
V1 W1
V2
Anschluss
connection Y -M1
M
3
1
-X100 2 3
UVWPE
-M1
4 5 PE
-W1
1
2
3
4
5
1
2
3
4
5
gnge
-H1
L1 L2 L3 L N PE
L
Stillstandheizung
Heater
N
Illustration 4
Connection is made on an auxiliary terminal strip in the terminal box.
[ 220-230V, 50Hz]
Type
Rated power
W
Ed 230
up to
25
Ed 4500
7 Special equipment
7.3 Limit switch
7.4 Standstill heating

KTR-STOP® TB Thruster
acc. to DIN 15430
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44414 EN
12 of 17
4
Please observe protection
note ISO 16016.
Drawn:
2020-11-02 Shg/Mro
Replacing:
KTR-N dated 2020-04-08
Verified:
2020-11-02 Shg
Replaced by:
The oil quantities given in table 2 are average quantities. They will decrease in case of thruster types
with valves and/or springs.
Ed-thrusters are filled with hydraulic oil, grade HL 10 DIN 51524 for temperature range from -20°C to
+50°C. For different temperature ranges special oils are required.
This "long-life" filling is not subjected to any wear or dirt during operation as long as the unit is in
perfect condition.
With refilling after repair any other brands than used for initial filling of category HL 10 DIN 51524
can be used. All bearing positions in the Ed thruster have an initial grease lubrication which means
that Ed thrusters are mainly maintenance-free.
Exceptions:
Thrusters as a firedamp-proof type are filled with flame retardant hydraulic liquid according to the
provisions of the German Mining Authority.
Table 2: Fill volumes for Ed thrusters 230/50 to Ed 3000/120, basic versions
Thruster-type
Fill volumes [L]
Thruster-type
Fill volumes [L]
Ed 230-50
1.6
Ed 2000-60
9.4
Ed 300-50
1.9
Ed 2000-120
9.4
Ed 500-60
4.2
Ed 3000-60
9.2
Ed 500-120
5.5
Ed 3000-120
9.2
Ed 800-60
4.2
Ed 4000-60
9.1
Ed 800-120
5.5
Ed 4000-120
9.1
Ed 1250-60
9.4
Ed 4500-60
9.1
Ed 1250-120
9.4
Ed 4500-120
9.1
STOP
Excess pressure is generated in the cylinder space of thrusters with operating temperature.
That is why there is the danger of burning with hot operating liquid when opening the filling
screws! Danger of burning!
Operating liquid (hydraulic oil) may only be inspected, refilled or drained in a deactivated
and cold state!
The thruster is filled functionally if the level of the operating liquid in vertical position with the lifting
rod retracted comes up to the lower edge within the filling hole.
The thrusters Ed 300/50, Ed 500/60 and Ed 800/60 must be filled to the overflow screw.
With too low filling the unit does not generate the full lifting force. With excessive filling an
impermissibly high internal pressure is generated in the unit.
8 Hydraulic liquid and lubricants as well as operating behaviour
8.1 Inspection of liquid level

KTR-STOP® TB Thruster
acc. to DIN 15430
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44414 EN
13 of 17
4
Please observe protection
note ISO 16016.
Drawn:
2020-11-02 Shg/Mro
Replacing:
KTR-N dated 2020-04-08
Verified:
2020-11-02 Shg
Replaced by:
If refilled locally the unit must be filled in vertical position to the overflow screw or filling limit of the
filling screw depending on the type.
To avoid potential air inclusions, several lifting motions must be performed. Afterwards the filling
level must be reinspected and refilled, if necessary.
Finally the filling screws and overflow screws (if existing) must be firmly tightened.
Temperature range
Operating liquid
Technical statement
-20 °C to +50 °C
HL 10, DIN 51524,
component 1
If the devices are in cold condition lifting
times may extend up to four times the
lifting times specified with minus
temperature range. The lowering times
remain unchanged.
above +50°C
special oil
Do contact the manufacturer
below -25°C 1)
special low-temperature oil
1) With ambient temperatures below -20°C the statements for vertical operating position apply.
The thruster can be tilted vertically up to 15° in the direction of the terminal box or installed
horizontally, while the terminal box must be on top for proper operation. The same applies for the
type with bottom eyes offset by 90°.
If a different mounting position is required, the device must be redesigned by the manufacturer.
!
With the majority of applications the thruster serves as a safety element. That is why
opening or disassembling the thruster may only be done by specialized staff of the
manufacturer and usually in the manufacturing plant only!
!
Lightly grease the fastening pins each of the device base and lifting rod bores to avoid
seizing and protect reliably against axial displacement!

Please observe the following KTR operating/assembly instructions:
KTR-N 44410 KTR-STOP® TB T Thruster brake
KTR-N 44411 KTR-STOP® TB S disk brake
8 Hydraulic liquid and lubricants as well as operating behaviour
8.2 Refilling
8.3 Operating behaviour depending on ambient temperature
9 Installation
9.1 Assembly

KTR-STOP® TB Thruster
acc. to DIN 15430
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44414 EN
14 of 17
4
Please observe protection
note ISO 16016.
Drawn:
2020-11-02 Shg/Mro
Replacing:
KTR-N dated 2020-04-08
Verified:
2020-11-02 Shg
Replaced by:
!
Before connecting make sure that the mains voltage and mains frequency correspond to the
details indicated in the type label!
!
Make sure with all cable connections that the swivelling motion of the thruster during
operation is not affected!
With normal delivery condition the three-phase motors are wired as a star connection. A wire cross-
section of 1.5 mm² is sufficient for all sizes. The terminals always have to be kept clean. The cover of
the terminal box must be sealed by a perfect seal.
The following items have to be reviewed:
•Inspection of oil level: The screw plug must be opened with the thruster in vertical position.
The housing must be filled to the lower edge of the filling hole of the opening (component 9).
The thrusters Ed 300/50, Ed 500/60 and Ed 800/60 must be filled to the overflow screw.
•The electrical connection must correspond to the details indicated in the type label.
•The oil filling screw, the terminal box cover and all screws and pins must be fastened
properly.
•All components mounted must be properly aligned. Free swivelling of the unit must be
ensured. Shear forces must not affect the piston rod.
If the thruster is provided with valves, they are set as follows –see illustration 5.
Illustration 5: Setting of globe (H) and lowering (S) valve
•The screw plug must be unscrewed by means of a suitable screwdriver.
•The globe valve (component H) or the lowering valve (component S) can be set via the
setting screw until the requested positioning time has been achieved. The thruster must be
switched on and off several times during setting.
9 Installation
9.2 Electrical connection
10 Initial start-up

KTR-STOP® TB Thruster
acc. to DIN 15430
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44414 EN
15 of 17
4
Please observe protection
note ISO 16016.
Drawn:
2020-11-02 Shg/Mro
Replacing:
KTR-N dated 2020-04-08
Verified:
2020-11-02 Shg
Replaced by:

Turning the setting screw to the right increases the positioning respectively
reset time.

Turning the setting screw left reduces the positioning respectively reset time.
•Do not untighten the slotted nut during this process!
•Reinstall the screw plug.
!
The positioning times depend on temperature and must be set on the thruster with
operating temperature! The setting screw may be unscrewed to the housing edge at the
maximum! The slotted nut must not be untightened in any case due to the risk of leakages!

Please observe the following KTR operating/assembly instructions:
KTR-N 44410 KTR-STOP® TB T Thruster brake
KTR-N 44411 KTR-STOP® TB S disk brake
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
Any metal components have to be cleaned and disposed of by scrap metal.
•Gaskets
Gaskets can be disposed of by residual waste.
•Electrical components
Electric components have to be treated as electric waste.
•Hydraulic oil
Hydraulic oils have to be collected in suitable tanks and disposed of by a waste disposal
company.
10 Initial start-up
11 Disposal

KTR-STOP® TB Thruster
acc. to DIN 15430
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44414 EN
16 of 17
4
Please observe protection
note ISO 16016.
Drawn:
2020-11-02 Shg/Mro
Replacing:
KTR-N dated 2020-04-08
Verified:
2020-11-02 Shg
Replaced by:
STOP
If the thruster needs to be disassembled for purpose of maintenance work, preparations
have to be made for retaining the weight of up to 40 kg.
The maintenance of thrusters is limited to a regular function and oil inspection. With normal
operating conditions it should be performed every six months. The intervals of oil change depend on
the conditions of application. If the oil shows significant modifications in viscosity or has become
significantly darker, it must be changed as follows:
•The dismounted thruster must be positioned horizontally with the oil filling hole at the bottom..
•After opening of the oil filling screw (component 9) the oil must drain.
•For a complete discharge the unit has to be held with the piston rod pointing vertically to the
bottom.
•Hold the unit with the piston rod pointing upwards and wait until the remaining oil has run out
of the cylinder, afterwards hold the unit pointing upwards. Repeat this process several times.
•Afterwards wash the housing with some clean oil.
•With the unit being in vertical position oil must be filled in either to the overflow screw or the
filling limit of the filling screw, each depending on the type. The hydraulic oil HL 10 DIN 51524
should be used here.
•Now some lifting motions should be made to fill the air chambers. The oil level should be
corrected, if necessary.
•The oil filling screw (component 9) must be retightened.
•The thruster can be mounted and put into operation.
12 Maintenance

KTR-STOP® TB Thruster
acc. to DIN 15430
Operating/Assembly instructions
KTR-N
Sheet:
Edition:
44414 EN
17 of 17
4
Please observe protection
note ISO 16016.
Drawn:
2020-11-02 Shg/Mro
Replacing:
KTR-N dated 2020-04-08
Verified:
2020-11-02 Shg
Replaced by:
Any trouble that cannot be sorted out by the measures specified in table 3 requires repair by
specialist staff. For this purpose it is necessary to observe the assembly, setting and testing
instructions of the manufacturer. Non-compliance with such instructions may cause damages and
loss of warranty. That is why any repairs on the thruster should be made by staff trained by the
manufacturer only.
Table 3: Examples of malfunction and rectification
Breakdowns
Causes
Elimination
Trouble: motor is
not running (piston
rod is not extended)
Interruption of supply
Search for and sort out interruption
Turn off by trigger unit
(motor protection switch)
Inspect motor protection switch and safety elements
Bad contact on the terminals
(corroded terminals)
Clean contacts
Rotor is jammed in the
stator, the bearings or in the
range of the impeller (pump)
Replace unit and send to KTR for repair
Unit is overloaded:
Sum of brake spring and
weight load is too high
Reduce load following the data of the unit
Lack of operating liquid
Refill operating liquid
Piston rod jams by external
effect
Search for cause of jamming in the components of the unit
and remove trouble –possibly inspect unit and machine
when disengaged (secure unit and remove pins on the rod
head)
Trouble: thruster
lifts slowly or by
jerks
See „unit overloaded“, „lack
of operating liquid“ and
„piston rod jammed“
See above
Interruption of supply (two-
phase system)
Search for and sort out interruption
Air in the pump circuit
Activate the unit in upright position several times and refill
operating liquid, if necessary
Operating liquid
escapes
On the piston rod seal
Replace unit and send to KTR for repair
On the filling screw
Inspect seal, fasten the screw
On the connection between
lower part (motor housing)
and upper part
Tighten the screw connection at a maximum of 49 Nm
Operating liquid in the
terminal box
Replace unit and send to KTR for repair
Metallic noise
Bearing damaged
Replace unit and send to KTR for repair
Activating the
safety elements
(motor protection
switch)
Short circuit of winding,
phases or contact voltage
Replace unit and send to KTR for repair
Increased current
consumption
Between two phases (short
circuit of winding)
Measuring the resistance –replace unit and send to KTR for
repair, if necessary
Between all phases (rotor
loops or is stuck)
Replace unit and send to KTR for repair
13 Trouble shooting