norbar PNEUTORQUE PTME-72-1000 Service manual

PNEUTORQUE®
FIXED NOSE EXTENSION
PTME-72-1000 STALL TOOLS
OPERATORS HANDBOOK (PART NO. 34305) Issue 1
(ENGLISH)
NORBAR TORQUE TOOLS LTD, Beaumont Road, Banbury, Oxfordshire, OX16 1XJ, UNITED KINGDOM
Tel : + 44 (0) 1295 270333, Fax : + 44 (0) 1295 753643
www.norbar.com

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ISSUE 1
02 2006
CONTENTS
PAGE
Safety 2
Introduction 3
Features and Functions 3
Set up Instructions 4
Operating Instructions 7
Maintenance 9
Specification 11
Declaration of Conformity 12
Trouble shooting 13
Glossary of terms 13
MODELS COVERED BY HANDBOOK:- ____________________________________________
PART
NUMBER DESCRIPTION MODEL MAXIMUM TORQUE TOOL TYPE
18064.B06 Bi-directional Pneutorque®
stall tool with fixed nose
extension
PTME-72-1000-B 1000 N.m Tool stalls against
external regulator
setting.
18064.F06 Forward (clockwise) only
Pneutorque® stall tool with
fixed nose extension.
PTME-72-1000-F 1000 N.m Tool stalls against
external regulator
setting.
18071.B06 Bi-directional wheel bolting
Pneutorque® stall tool with
modified reaction foot
PTME-72-1000-B 1000 N.m Tool stalls against
external regulator
setting.
The ‘06’ suffix in the part number indicates a ” A/F drive square size.

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ISSUE 1
02 2006
SAFETY
IMPORTANT: DO NOT OPERATE THE TOOL BEFORE READING THIS HANDBOOK. FAILURE TO
DO SO MAY RESULT IN PERSONAL INJURY OR DAMAGE TO THE TOOL.
This tool is intended for use with threaded fasteners. Any other use is not recommended.
The use of ear protectors is recommended.
Do not use tool in potentially explosive atmosphere as these tools contain grease, which may cause an
explosion hazard in the presence of pure oxygen. These tools also contain aluminium alloy components
which may cause a hazard in certain explosive environments.
Be aware of unexpected tool movement due to reaction forces as this may cause injuries. Failure of the
drive shaft may also cause unexpected tool movement.
Isolate the tool from all energy sources before changing or adjusting the drive square or socket.
There is a risk of crushing between the reaction foot and work piece.
Keep hands away from reaction foot.
Keep hands away from tool output.
Keep loose clothing, hair, etc. from being caught in any rotating part of the tool.
Ensure all hoses are correctly fitted before switching on the mains air supply. This avoids the risk of injury
by whipping air hoses.
Use only sockets and adaptors which are in good condition and are intended for use with power tools.
Pneutorque® Wrenches are non impacting, torque controlled bolt tightening tools and must always be
operated with the following:-
•Clean dry air supply with a minimum flow of 19 litres/sec (40 CFM).
•Air Regulator and optional Lubricator Unit 1/2” Bore (12 mm).
•Impact or high quality sockets.
•Reaction Arm.

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ISSUE 1
02 2006
INTRODUCTION
The Pneutorque® 52mm series are air driven power tools designed for applying torque to wheel nuts in
the range of 200 N.m to 1000 N.m This tool uses the air pressure set on an external pressure regulator to
determine the stall torque.
PARTS INCLUDED:-____________________________________________________________
PART NUMBER DESCRIPTION QUANTITY
180**.*06 Pneutorque® 1
18747 Lifting Bracket 1
34305 Operators Handbook 1
ACCESSORIES / SPARES:- _____________________________________________________
PART NUMBER DESCRIPTION
16036 Lubro Control Unit
18591 Silencer
26287 Spring Pin for drive shaft.
77112.2 Drive Shaft (3/4”)
FEATURES AND FUNCTIONS
REPLACEABLE DRIVE SHAFT
All tools are fitted with a ” (19mm) drive shaft that can easily be replaced.
TRIGGER
The trigger controls the flow of air. The more the trigger is pressed the more air flows into the tool. This
allows for slow positioning of socket and reaction plate. Once positioning is complete, the trigger must be
fully depressed for correct torque application.
CLOCKWISE / COUNTER-CLOCKWISE SELECTOR
Tools fitted with this option can be used for releasing bolts as well as tightening. The gearing inside the
housing is biased towards counter-clockwise drive to give a higher torque for releasing the fastener.
LIFTING BRACKET
The metal lifting bracket can be used to suspend the tool from a balancer.

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ISSUE 1
02 2006
SET UP INSTRUCTIONS
WARNING: TO AVOID HAZARD FROM WHIPPING AIR HOSES MAKE ALL
CONNECTIONS TO THE TOOL BEFORE TURNING ON THE AIR
SUPPLY.
Make sure all air hoses are clean and free from dirt.
1. Connect the tool air inlet hose (C) to the outlet side of the Lubro control unit (B), observing air flow
direction arrows. Use a ” bore hose with a maximum length of 3m.
TIP. To connect the air inlet hose to a ” bore hose use a ” BSP Male/Male connector. A pair of
spanners will be required to perform this task (22mm (7/8”) A/F and 24mm (15/16”) A/F open-
ended spanners)
2. Connect the inlet side of the Lubro control unit (B) to the mains air supply (A) using a minimum hose size
of ” bore (12mm). Avoid using ” bore hoses of longer than 5 meters from the supply to the lubro
control unit as this will reduce the performance of the tool.
Figure 1
3. Periodically, check the oil level in the lubricator and fill to the correct level if required. (see
MAINTENANCE section)
4. Fit the lifting bracket (D) into the 2 holes in the side of the handle.
NOTE: Lifting bracket securing screws MUST be torqued up to 5 N.m.
TIP. The lifting bracket should be used only in conjunction with a suitable balancer. If the tool is to be
used without a balancer or hanging device there is no need to fit the lfting bracket to the tool.

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ISSUE 1
02 2006
SETTING CLOCKWISE/COUNTER-CLOCKWISE OPERATION_________________________
Clockwise
(Arrow towards drive square)
Figure 2a
Counter-clockwise
(Arrow away from drive square)
Figure 2b
TIP: To help set the clockwise / counter-clockwise operation run the tool in neutral position before
re-engaging.
Neutral position
Figure 2c
WARNING: FAILURE TO FULLY ENGAGE THE CLOCKWISE/COUNTER-
CLOCKWISE OPERATION SELECTOR WILL RESULT IN DAMAGE TO
THIS PART OF THE GEARBOX.
SETTING TORQUE FOR BOLT TIGHTENING _______________________________________
The tools use the air pressure set on an external pressure regulator unit to determine the stall torque.
Pneutorques® are supplied with an Air Pressure Graph which relates torque output to air pressure. Set
the torque output as follows:-
1. Ensure the Clockwise/Counter-clockwise Selector (if fitted) is correctly set.
2. Establish the air pressure required using the Air Pressure Graph.
3. With the tool running, adjust the pressure regulator until the correct figure is shown on the gauge.
IMPORTANT: THE WRENCH MUST BE FREE RUNNING WHILE ADJUSTING THE AIR PRESSURE
TO GIVE THE CORRECT SETTING.
IMPORTANT: ENSURE THE LUBRO CONTROL UNIT IS SUPPLYING APPROXIMATELY SIX
DROPS OF OIL PER MINUTE WHILE THE TOOL IS FREE RUNNING.

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ISSUE 1
02 2006
SETTING TORQUE FOR RELEASING BOLT________________________________________
NOTE: THIS PROCEDURE IS ONLY APPLICABLE TO BI-DIRECTIONAL TOOLS.
The tools are designed to give a slightly higher torque in
counter-clockwise rotation. This may allow some tight bolts
to be released without the need to set a higher air pressure.
1. Ensure the Clockwise/Counter-clockwise Selector is correctly set.
2. Pull trigger to loosen fastener.
TIP: Increase air pressure slightly if fastener will not release.
Figure 3
WARNING: EXCEEDING THE MAXIMUM AIR PRESSURE AS STATED ON THE
TOOL WILL CAUSE OVERLOADING AND MAY LEAD TO SERIOUS
DAMAGE.
WARNING: CHANGING THE MAINS AIR PRESSURE AFTER SETTING THE
LUBRO CONTROL UNIT WILL CHANGE THE STALL TORQUE
VALUE.
TORQUE REACTION ___________________________________________________________
When the Pneutorque® is in operation the reaction foot rotates in the opposite direction to the output drive
square and must be allowed to rest squarely against a solid object or surface adjacent to the bolt to be
tightened. (See figure 4).
WARNING: ALWAYS KEEP HANDS CLEAR OF THE REACTION FOOT WHEN THE TOOL IS IN
USE OR SERIOUS INJURY MAY RESULT.
Figure 4a (Clockwise) Figure 4b (Counter-clockwise)

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ISSUE 1
02 2006
OPERATING INSTRUCTIONS
WARNING: KEEP HANDS CLEAR OF THE REACTION FOOT.
WARNING: WHEN USING THIS TOOL IT MUST BE SUPPORTED AT ALL TIMES
IN ORDER TO PREVENT UNEXPECTED RELEASE IN THE EVENT OF
FASTENER OR COMPONENT FAILURE.
A. TIGHTENING ______________________________________________________________
1. Fit Pneutorque® with the correct size impact or high quality socket to suit fastener. Ensure socket is
in good condition.
2. Ensure the Clockwise/Counter-clockwise Selector is correctly set.
3. Rotate the Handle into a convenient position relative to the reaction foot. Fit the tool onto the
fastener to be tightened with the reaction foot adjacent to the reaction point. See Figure 5.
4. Adopt a suitable posture to counteract normal or unexpected movement of the tool due to reaction
forces.
5. Squeeze the Trigger partially to bring the Reaction foot into contact with the reaction point.
6. Fully depress trigger and keep fully depressed until tool stalls then release trigger.
If the trigger is not fully depressed full torque will not be applied to the fastener.
7. Remove tool from fastener.
Figure 5

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ISSUE 1
02 2006
B. RELEASING _______________________________________________________________
1. Fit the Pneutorque® with the correct size impact or high quality socket to suit the fastener to be
released. Ensure socket is in good condition.
2. Ensure the clockwise/counter-clockwise selector is correctly set.
3. Rotate the handle into a convenient position relative to the reaction foot. Fit the tool onto the fastener
to be released with the reaction foot adjacent to the reaction point. See Figure 6.
4. Adopt a suitable posture to counteract normal or unexpected movement of the tool due to reaction
forces.
5. Squeeze the trigger partially to bring the reaction foot into contact with the reaction point.
6. Fully depress trigger and keep fully depressed until bolt releases.
TIP: If unable to release the bolt increase the air pressure to the tool. Do not exceed max air
pressure as stated on the tool.
WARNING: EXCEEDING THE MAXIMUM AIR PRESSURE WILL CAUSE
OVERLOADING AND MAY LEAD TO SERIOUS DAMAGE.
WARNING: CHANGING THE MAINS AIR PRESSURE AFTER SETTING THE
PRESSURE REGULATOR WILL CHANGE THE STALL TORQUE
VALUE.
Figure 6

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ISSUE 1
02 2006
MAINTENANCE
To maintain optimum performance and safety, regular maintenance needs to be carried out. The only
user maintenance required on these tools is the replacement of drive shaft and the silencer. Any other
maintenance or repairs should be carried out by Norbar or a Norbar approved agent and should form part
of a service. Service intervals will depend on the type of usage of the tools and the environment in which
they are being used.
AIR LUBRICATION:-____________________________________________________________
Add Shell Tellus 15 or equivalent good quality hydraulic oil to the Lubro unit.
NOTE: Lubro unit should run at 6 drops/minute
GEARBOX:-___________________________________________________________________
Under normal operating conditions it is not necessary to re-grease the gearbox. The gearbox contains
Lubcon Turmogrease Li 802 EP or equivalent good quality grease.
SILENCER:-___________________________________________________________________
The silencer (#18591) must be changed every 12 months. This may be more frequent for high tool usage
or dirty environments.
TIP: Change silencer with tool upside
down, as shown, to ensure
internal parts (spring & valve) are
kept in place.
1. Remove M4 screw (A) (#25381.10) using
a 2.5mm hexagon key.
2. Remove pin (B) (#26284) using a pin
punch.
3. Pull out air inlet tube (D) with base plate
& silencer.
4. Remove silencer (E) from air inlet tube.
5. Fit new silencer (#18591) over air inlet
tube.
6. Fit air inlet tube assembly (C, D & E) into
handle against spring resistance.
7. Fit pin (B) with a hammer.
8. Fit screw (A) hand tight. Do not over
tighten this screw as it is likely to break
the base plate moulding.(0.5N.m MAX)
TIP: When refitting air inlet tube
assembly into handle care should
be taken to ensure correct
alignment between air inlet tube &
spring. It may be easier to fit the
spring into air inlet tube first and
secure with a small amount of
grease.
Figure 7

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02 2006
DRIVE SHAFT:-________________________________________________________________
To avoid internal damage (especially due to torque overload), the output drive shaft has been designed to
shear first. This saves major internal damage and allows easy shaft removal.
Figure 8
To replace drive shaft:
Support tool securely in a horizontal position, before commencing this operation
1. Using a suitable punch, remove spring pin (A).
2. Remove remainder of drive shaft (B).
Again securely support the tool in a horizontal position.
3. Taking new drive shaft (B) (#77112.2) insert splined end into the reaction foot (C) insuring correct
engagement of spline and that the drive shaft is pressed fully home.
4. To secure drive shaft insert new pin (A) (#26287) with suitable punch.
CLEANING:- __________________________________________________________________
Keep the tool in a clean condition to aid safety. Do not use abrasives or solvent based cleaners.
TIP: Holding the tool vertically with the reaction foot downward, lightly tap the complete tool on the
bench, until the remainder of the broken shaft drops out.

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02 2006
SPECIFICATIONS
RANGE
MODEL MIN MAX MAXIMUM
OVERLOAD TOOL SPEED
(FREE RUNNING AT MAX. AIR
PRESSURE)
PTME-72-1000-* 200 N.m 1000 N.m 1100 N.m 125 r/min
Repeatability: ± 5%
Air Supply: Maximum pressure – 6.3 bar (For maximum torque capacity).
Recommended Lubrication: Shell Tellus 15 for the Lubro Control Unit.
Temperature Range: 0°C to +50°C (operating). -20°C to +60°C (storage).
Maximum Operating Humidity: 85% Relative Humidity @30°C.
Case Materials / Finish: Handle: Aluminium casting with epoxy powder finish.
Direction Gearbox: Aluminium with epoxy powder finish.
Annulus: Alloy steel with nickel plate finish.
Reaction Foot: Alloy steel with epoxy powder finish.
MODEL DIRECTION WEIGHT DIMENSIONS
PTME-72-1000-B Bi-directional. 7.16 kg (15.8lb) 385mm x 72mm wide x 255mm (min)
PTME-72-1000-F Forward (clockwise) only. 6.96 kg (15.4lb) 340mm x 72mm wide x 255mm (min)
Maximum Vibration at Handle: < 2.5m/s2
Tested in accordance with ISO 8662-7 Hand Held portable tools –
Measurement of vibrations at the handle.
Sound Pressure Level: 83 dBA measured at 1m equivalent continuous A weighted sound.
Tested to BS ISO 3744: 1994 Acoustics – Determination of sound
power levels of noise sources using sound pressure – Engineering
method in an essentially free field over a reflecting plane. Test
conducted in free running condition with a supply pressure of 6.3 bar.
Environment: Indoor use within a light industrial environment.
Machinery Directive: In conformance with:
BSEN 792-6:2000 Hand-held non-electric power tools.
Safety requirements. Assembly power tools for threaded fasteners.
Due to continuous improvement all specifications are subject to change without prior notice.

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02 2006
TROUBLE SHOOTING
The following is only a guide, for more complex faults please contact your local Norbar distributor or
Norbar directly.
PROBLEM LIKELY SOLUTIONS
Tool output does not rotate when trigger pulled. Check air supply is functioning & connected.
Check air pressure setting (at least 1 bar).
Check correct setting of direction knob.
Output drive shaft sheared, needs replacing.
Gear train or air motor is damaged
Drive shaft sheared. See maintenance section to replace.
Tool does not stall. Tool has not achieved torque, increase air
pressure.
Fastener sheared or thread stripped.
Gear train or air motor is damaged
GLOSSARY OF TERMS
WORD OR TERM MEANING
Air pressure graph Graph supplied with Stall only tool to show air pressure setting against required
torque.
Bi-directional Tool capable of Clockwise & Counter-clockwise square rotation.
Lubro Control Unit Unit to provide air filtering and lubrication along with pressure regulation. Not
supplied with tool.
Pneutorque® Product name.
Reaction foot Device to counteract applied torque.