norbar PTM-72 Series Service manual

PNEUTORQUE®
PTM SERIES
72-1000 & 72-2000 STALL TOOLS
OPERATORS HANDBOOK (PART NO. 34313)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
09 2005
CONTENTS
PAGE
Safety 2
Introduction 3
Features and Functions 4
Set up Instructions 4
Operating Instructions 10
Maintenance 12
Specification 14
Declaration of Conformity 15
Trouble shooting 16
Glossary of terms 16
MODEL NUMBERS COVERED BY MANUAL:-______________________________________
PART
NUMBER
DIRECTION MODEL MAXIMUM
TORQUE TOOL TYPE
18072.F06 Forward (Clockwise) only.
18072.B06 Bi-directional.
PTM72-1000
Stall Tool 1000 N.m
Tool stalls
against external
regulator setting.
18062.F08 Forward (Clockwise) only.
18062.B08 Bi-directional.
PTM72-2000
Stall Tool 2000 N.m
Tool stalls
against external
regulator setting.
The ‘06’ suffix in the part number indicates a 3/4” A/F drive square size.
The ‘08’ suffix in the part number indicates a 1” A/F drive square size.

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09 2005
SAFETY
IMPORTANT: DO NOT OPERATE THE TOOL BEFORE READING THESE INSTRUCTIONS. FAILURE
TO DO SO MAY RESULT IN PERSONAL INJURY OR DAMAGE TO THE TOOL.
This tool is intended for usewith threaded fasteners. Any other use isnot 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 square 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 bar and work piece.
Keep hands away from reaction bar.
Keep hands away from tool output.
Keep loose clothing, hair, etc. from being caught in any rotating part of the tool.
These tools require a reaction bar.See section on Torque Reaction.
Ensure all hoses are correctly fitted before switching on the mains air supply. This avoidsthe 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
09 2005
INTRODUCTION
The Pneutorque®PTM72mm series are air driven power tools designed for applying torque to threaded
fasteners. There are models to cover torque capacities of 1000 N.m and 2000 N.m. These models are
available in 2types:
Stall Tool
These tools use the air pressure set on an external pressure regulator to determine the stall torque.
Stall Tool with Internal Regulator
These tools use an in-built pressure regulator to control the stall torque.This allows the tool to be set
without the need for a separate external pressure regulator.
PARTS INCLUDED:-____________________________________________________________
PART NUMBER DESCRIPTION QUANTITY
180***.*08/06 Pneutorque®1
18494 Cranked Reaction Arm 1
18747 Lifting Bracket 1
26486 Reaction Plate Retaining Circlip 1
34313 Operators Handbook 1
ACCESSORIES:-_______________________________________________________________
PART NUMBER DESCRIPTION
18349.006 6” Nose Extension
18349.009 9” Nose Extension
18349.012 12” Nose Extension
18779 ¾” Drive Square (Not 2000)
18492 1” Drive Square
18292 Single-sided Reaction Plate
18293 Double-sided Reaction Plate
18266 Silencer
16036 Lubro Control Unit
*18290 Reaction Adaptor
*18298 Reaction Tube
* Requires both parts to form a suitable reaction device.

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09 2005
FEATURES AND FUNCTIONS
REPLACEABLE DRIVE SQUARE
All tools are fitted with either ¾” (19mm) or 1” (25.4mm) drive square 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 bracket can be used to suspend the tool from a balancer.
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 pressure regulator unit (B), observing air flow
direction arrows. Use a ½” bore hose with a maximum length of 3m.
TIP. To connect the air inlet hose to a 1/2” bore hose use a ½” 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 pressure regulator unit (B) to the mains air supply (A) using a minimum hose
size of ½” bore (12mm). Avoid using ½” bore hoses of longer than 5 meters from the supply to the
pressure regulator unit as this will reduce the performance of the tool.

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ISSUE 1
09 2005
Figure 1
3. If running the tool with oil, check the oil level in the lubricator and fill to the correct level if required. (see
MAINTENANCE section)
TIP. These tools have been designed to run with a clean, dry, unlubricated air supply if required, but this
is not essential. It is best to run a tool with unlubricated air from new as this avoids early oil
deposits solidifying and clogging the vane slots.
4. Fit reaction plate (D) over drive square to engage reaction splines. Fit circlip (#26486) supplied.
5. Fit lifting bracket (E) into two holes in the side of the handle.
NOTE: LIFTING BRACKET SECURING SCREWS MUST BE TORQUED UP TO 5 N.M.
TIP. The hanger 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 hanger to the tool.

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ISSUE 1
09 2005
TORQUE REACTION ___________________________________________________________
When the Pneutorque®is in operation the reaction arm 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 2).
WARNING: ALWAYS KEEP HANDS CLEAR OF THE REACTION ARM WHEN THE TOOL IS IN USE
OR SERIOUS INJURY MAY RESULT.
Figure 2a (Clockwise) Figure 2b (Counter-clockwise)
WARNING: CARE MUST BE TAKEN TO ENSURE THAT THE REACTION ARM IS
ONLY USED WITHIN THE LIMITATIONS SHOWN IN FIGURE 3.
For special applications or where extra deep sockets must be used the standard arm may be extended but
only within the limitations shown on Figure 3.
Alternative reaction devices are available.
WARNING: FAILURE TO OBSERVE THE LIMITATIONS SHOWN IN FIGURE 3 WHEN
MODIFYING STANDARD REACTION ARMS MAY RESULT IN
PREMATURE WEAR OR DAMAGE TO THE TOOL.
Standard drive square extensions MUST NOT be used as these will cause serious damage to the tool output
drive. A range of nose extensions is available for applications where access is restricted. These are
designed to support the final drive correctly.
Figure 3
Torque Reaction
should be taken in the
shaded areas only.
Extra Length Socket
Standard
Length Socket

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ISSUE 1
09 2005
SETTING CLOCKWISE/COUNTER-CLOCKWISE OPERATION _______________________
Clockwise
(Arrow towards drive square)
Figure 4a
Counter-clockwise
(Arrow away from drive square)
Figure 4b
TIP:To help set the clockwise / counter-clockwise operation run the tool in neutral position before
re-engaging.
Neutral position
Figure 4c
WARNING: FAILURE TO FULLY ENGAGE THE CLOCKWISE/COUNTER-
CLOCKWISE OPERATION SELECTOR WILL RESULT IN DAMAGE TO
THIS PART OF THE GEARBOX.

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ISSUE 1
09 2005
SETTING TORQUE FOR BOLT TIGHTENING______________________________________
STALL TOOLS ________________________________________________________________
These tools use the air pressure set on an external pressure regulator unit to determine the stall torque.
They 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.
STALL TOOLS FITTED WITH TORQUE REGULATOR ______________________________
The tool can be set in one of two ways.
A. The tool can be set against the Air Pressure Graph in the same way as the stall tool without the internal
regulator as long as the regulator valve is fully open. (This is factory set fully open).
B. To set the torque regulator a suitable calibration device will be required. (see Glossary of Terms) Set the
tool by the following procedure.
1. Ensure the Clockwise/Counter-clockwise
Selector (if fitted) is correctly set.
2. If the tool is connected up to the mains air
supply, switch off the supply and press the
trigger to release any air trapped between
the pressure regulator and the tool. Remove
the air hose from the tool.
3. Fit the adjusting tool J2364 into the air inlet
tube until the box spanner engages onto the
locknut (A). Loosen the locknut (C) by 90
degrees.
4. Engage the screwdriver (D) into the slot in
the end of the valve body (B). Rotate
screwdriver (D) to change torque setting.
5. Tighten locknut (C) and remove adjusting
tool.
6. Re-attach the tool to the air supply and
check the stall torque against acalibration
device. This process may take several
adjustments to achieve the final setting.
7. The tool is now ready for use.
Figure 5

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ISSUE 1
09 2005
NOTE: THE TORQUE REGULATOR WILL NOT GIVE FULL CONTROL OVER THE ENTIRE RANGE
OF THE TOOL. THE RANGE OF THE REGULATOR IS FROM FULL TORQUE TO
APPROXIMATELY 50% OF FULL TORQUE VALUE.
TIP: If a lower torque level is required it may be achieved by reducing the mains air pressure to the tool.
NOTE:REPEATABILITY OF THE TOOL MAYBE AFFECTED BY THE USE OF THIS REGULATOR.
IMPORTANT: IF RUNNING THE TOOL WITH LUBRICATION, CHECK THAT THE LUBRO CONTROL
UNIT IS SUPPLYING APPROXIMATELY SIX DROPS OF OIL PER MINUTE WHILE THE
TOOL IS FREE RUNNING.
IF THE TOOL IS USED WITH AN INTERNAL TORQUE REGULATOR THE TOOL MUST
BE CALIBRATED TO A PRE-SET TORQUE VALUE ON A SUITABLE CALIBRATION
FIXTURE –IF IN DOUBT CONTACT YOUR DISTRIBUTOR.
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 6
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.

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ISSUE 1
09 2005
OPERATING INSTRUCTIONS
WARNING: KEEP HANDS CLEAR OF THE REACTION ARM.
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.
2. Ensure the Clockwise/Counter-clockwise Selector is correctly set (if fitted).
3. Rotate the Handle into a convenient position relative to the reaction arm. Fit the tool onto the fastener
to be tightened with the reaction arm adjacent to the reaction point. See Figure 7.
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 Arm 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 7

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ISSUE 1
09 2005
B. RELEASING _______________________________________________________________
NOTE: ONLY FOR BI-DIRECTIONAL TOOLS
1. Fit the Pneutorque® with the correct size impact or high quality socket to suit the fastener to be
released.
2. Ensure the clockwise/counter-clockwise selector is correctly set.
3. Rotate the handle into a convenient position relative to the reaction arm. Fit the tool onto the fastener to
be released with the reaction arm adjacent to the reaction point. See Figure 8.
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 arm 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 use excessive air
pressure.
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 8

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ISSUE 1
09 2005
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 squares 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: The tools may be run without air lubrication to avoid the possibility of oil mist.
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 9

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09 2005
DRIVE SQUARE:- ______________________________________________________________
To avoid internal damage (especially due to torque overload), the output drive square has been designed to
shear first. This saves major internal damage and allows easy square removal.
Figure 10
The drive square can be replaced with either a ¾” drive square (#18779), or a 1” drive square (#18492). A new
retaining screw (#25352.45) is supplied with the square.
To replace drive square:
1. Use 4mm hexagon key to remove screw.
2. Remove drive square.
3. Fit new drive square.
4. Fit new screw and tighten to 4 N.m -5 N.m.
TIP:If the square has sheared it may be necessary to use pliers to remove the broken parts.
CLEANING:-___________________________________________________________________
Keep the tool in a clean condition to aid safety. Do not use abrasives or solvent based cleaners.

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ISSUE 1
09 2005
SPECIFICATIONS
RANGE
MODEL MIN MAX
MAXIMUM
OVERLOAD
TOOL SPEED
(FREE RUNNING AT MAX. AIR PRESSURE)
1000Nm 200 N.m1000 N.m1100 N.m125 r/min
2000Nm 400 N.m2000 N.m2200 N.m60 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 Plate: Alloy steel with epoxy powder finish.
TYPE MODEL WEIGHT DIMENSIONS
Forward (Clockwise) only 18072.F06 6.0 kg (13.4lb) 315mm x 75mm wide x 255mm
Bi-directional 18072.B06 6.2 kg (14.4lb) 360mm x 75mm wide x 255mm
Forward (Clockwise) only 18062.F08 6.3 kg (14.6lb) 345mm x 75mm wide x 255mm
Bi-directional 18062.B08 6.5 kg (15.0lb) 390mm x 75mm wide x 255mm
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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09 2005
Declaration of Conformity
Manufactured by Norbar Torque Tools Ltd.,
Beaumont Road, Banbury, Oxon, OX16 1XJ
The Directives covered by this Declaration
Safety of Machinery Directive, 98/37/EEC
The Equipment Covered by this Declaration
Equipment: PTM –72 –XXXX -XX
Model No.(s): 18072.F06, 18072.B06,
18062.F08, & 18062.B08.
The Basis on which Conformity is being Declared
The equipment identified above is in compliance with the protection requirements of the above directives, and
the following standards have been applied:-
EN 792-6:2000 Hand-held non-electric power tools –Safety requirements
Pt 6: Assembly power tools for threaded fasteners
The technical documentation required to demonstrate that the products meet the requirements of the above
Directives has been compiled and is available for inspection by the relevant enforcement authorities. The CE
mark was first applied in: 2005.
Signed: Full Name: Trevor Lester
Date: 19 September 2005 Authority: Compliance Engineer

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09 2005
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 square sheared, needs replacing.
Gear train or air motor is damaged
Drive square 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 filtering and lubrication along with pressure regulation. Not supplied
with tool.
Oil free air Regulated air without oil lubrication.
Pneutorque®Product name.
Reaction Arm Device to counteract applied torque.
Calibration device Torque calibration system comprising of suitable torque transducer and display
capable of measuring peak torque along with a suitable run down fixture or test
fastener. Alternatively use the torque transducer on the fastener being tightened.