norbar PNEUTORQUE PT 72/1000 Service manual

PNEUTORQUE®
PT 72 SERIES
500/1000/1500/2000/4500 STALL TOOLS
OPERATORS HANDBOOK (PART NUMBER 34309)
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

PT72 SERIES OPERATORS HANDBOOK PAGE 1 OF 14
ISSUE 1
08 2005
CONTENTS
PAGE
Safety 2
Introduction 3
Features and Functions 3
Set up Instructions 4
Operating Instructions 8
Maintenance 10
Specification 12
Declaration of Conformity 13
Trouble shooting 14
Glossary of terms 14
MODELS COVERED BY HANDBOOK:- ___________________________________________
This handbook covers all “PT 72mm series” tools supplied with pistol grip handles; including the following:
PART NUMBER MODEL SQUARE MAXIMUM TORQUE
18023 PT 72/500
18023.AUT PT 72/500 Auto 2 speed 3/4” 500 N.m
18022 PT 72/1000
18022.AUT PT 72/1000 Auto 2 speed 3/4” 1000 N.m
18026 PT 72/1000
18026.AUT PT 72/1000 Auto 2 speed 1” 1000 N.m
18021 PT 72/1500
18021.AUT PT 72/1500 Auto 2 speed 1” 1500 N.m
18033 PT 72/2000
18033.AUT PT 72/2000 Auto 2 speed 1” 2000 N.m
18038 PT 4500
18038.AUT PT 4500 Auto 2 speed 1” 4500 N.m
PT 72mm series tools are also supplied in a ‘remote’ form without a handle. These are given a part
number suffix ‘X’ (e.g. *****.X) and are covered by operators handbook part number 34310.

PT72 SERIES OPERATORS HANDBOOK PAGE 2 OF 14
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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 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 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 avoids the risk of injury
by whipping air hoses.
Unexpected direction of inserted tool movement can cause a hazardous situation.
Use only sockets and adaptors which are in good condition and are intended for use with power tools.
Pneutorque® Wrenches are reversible, non impacting, torque controlled bolt tightening tools and must
always be operated with the following:-
• Clean dry air supply with a minimum flow of 11 litres/sec (23 CFM).
• Lubro Control Unit or similar Filter, Regulator and Lubricator Unit 1/2” Bore (12 mm).
• Impact or high quality sockets.
• Reaction Arm.

PT72 SERIES OPERATORS HANDBOOK PAGE 3 OF 14
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INTRODUCTION
The Pneutorque® 72mm series are air driven power tools designed for applying torque to threaded fasteners.
An external pressure regulator (Lubro control unit) is needed; this allows the air pressure to be adjusted to
determine the stall torque from the graph provided. There are models to cover torque capacities of 500 N.m to
4500 N.m.
PARTS INCLUDED:- ____________________________________________________________
PART NUMBER DESCRIPTION QUANTITY
180***.*** Pneutorque® 1
16673 Reaction Arm (Only PT 4500) 1
18290 Reaction Plate (Except PT 4500) 1
18298 Reaction Arm (Except PT 4500) 1
18343.148 Lifting Handle (Only PT 72/****) 1
18343.220 Lifting Handle (Only PT 72/****.AUT) 1
18344.220 Lifting Handle (Only PT 4500) 1
26482 Reaction Plate Retaining Circlip (Only PT 4500) 1
26588 Reaction Plate Retaining Circlip (Except PT 4500
)
1
34309 Operators Handbook 1
ACCESSORIES:- _______________________________________________________________
PART NUMBER DESCRIPTION
18349.006 6” Nose Extension
18349.009 9” Nose Extension
18349.012 12” Nose Extension
18349.015 15” Nose Extension
18349.018 18” Nose Extension
18221 ¾” Drive Square
18220 1” Drive Square
18292 Single-sided Reaction Plate
18293 Double-sided Reaction Plate
18286 Lifting Arm
18266 Silencer
16036 Lubro Control Unit
FEATURES AND FUNCTIONS
REPLACEABLE DRIVE SQUARE
All tools are fitted with a ¾” (19mm) or 1” (25mm) 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
This option can be used for releasing bolts as well as tightening. The selector is located at the back of the
handle for easy access.
GEARBOX
For safety the gearbox and handle can turn independently, so torque reaction is never transmitted back to the
operator.
LIFTING HANDLE
The lifting handle allows comfortable and safe use of the tool.

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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 (A.) to the outlet side of the pressure regulator unit, 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 to the mains air supply 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.
Figure 1
3. Check the oil level in the lubricator and fill to the correct level. (See
MAINTENANCE section).
4. Attach the Reaction Arm (B.) to Reaction Plate (C.) adjacent to the
Output Drive (D.) of wrench ensuring the Locking Plunger (E.) is
correctly engaged in the Reaction Arm. Fit circlip to secure reaction
plate.
5. If required fit lifting handle (Figure 2) to top of the Air Motor Housing
(F.). Adjust the handle position so the wrench can be held
comfortably. Tighten the socket screws securely.
Figure 2
Output Square
Drive (D.)
Handle
(I.)
Trigger (H.)
Locking Plunger
(E.)
Reaction Arm
(B.)
Reaction Plate
(C.)
Clockwise/Counter
- Clockwise Switch
(
G.
)
A
ir Motor Housing (F.)
A
ir Inlet (A.)

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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 3).
WARNING: ALWAYS KEEP HANDS CLEAR OF THE REACTION ARM WHEN THE TOOL IS IN
USE OR SERIOUS INJURY MAY RESULT.
Figure 3
WARNING: CARE MUST BE TAKEN TO ENSURE THAT THE REACTION ARM IS
ONLY USED WITHIN THE LIMITATIONS SHOWN IN FIGURE 4.
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 4. Alternative reaction devices are available.
WARNING: FAILURE TO OBSERVE THE LIMITATIONS SHOWN IN FIGURE 4
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 4

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SETTING CLOCKWISE/COUNTER-CLOCKWISE OPERATION ________________________
WARNING: FAILURE TO FULLY ENGAGE THE CLOCKWISE/COUNTER-
CLOCKWISE OPERATION SELECTOR WILL RESULT IN
DAMAGE TO THE SELECTOR VALVE.
SETTING PROTRACTOR ______________________________________________________
The PT 4500 tools have an integral angle protractor for easy
torque and angle tightening.
Figure 7
Figure 5
Clockwise
Figure 6
Counter-clockwise

PT72 SERIES OPERATORS HANDBOOK PAGE 7 OF 14
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08 2005
SETTING TORQUE FOR BOLT TIGHTENING ______________________________________
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 (Figure 5 & Figure 6) 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.
WHILE THE WRENCH IS FREE RUNNING CHECK THAT LUBRO CONTROL UNIT IS
SUPPLYING APPROXIMATELY SIX DROPS OF OIL PER MINUTE.
SETTING TORQUE FOR RELEASING BOLT_______________________________________
1. Ensure the Clockwise/Counter-clockwise Selector (Figure 5 & Figure 6) is correctly set.
2. Pull trigger to loosen fastener.
TIP: Increase air pressure slightly if fastener will not release.
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.

PT72 SERIES OPERATORS HANDBOOK PAGE 8 OF 14
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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.
WARNING: CHANGING THE MAINS AIR PRESSURE AFTER SETTING THE
PRESSURE REGULATOR WILL CHANGE THE STALL TORQUE
VALUE.
A. TIGHTENING_____________________________________________________________
1. Fit Pneutorque® with the correct size impact or high quality socket.
2. Ensure the Clockwise/Counter-clockwise Selector is correctly set.
3. Rotate tool and reaction arm into a convenient position.
Fit the tool onto the fastener.
Locate reaction arm adjacent to the reaction point.
4. Adopt a suitable posture to counteract normal or
unexpected movement of the tool due to reaction forces.
5. Gently press Trigger to bring the reaction arm into contact with the reaction point.
6. Fully press trigger and keep fully depressed until tool stalls then release trigger.
If the trigger is not fully pressed full torque will not be applied to the fastener.

PT72 SERIES OPERATORS HANDBOOK PAGE 9 OF 14
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7. For angle tightening (PT 4500) complete the following:
a. Set angle protractor to 0°.
b. Note air setting on Lubro Control Unit.
c. Increase air pressure on Lubro Control Unit.
d. Press trigger and monitor angle.
e. Release trigger at required angle.
f. Reset air pressure on Lubro Control Unit.
8. Remove tool from fastener.
B. RELEASING _____________________________________________________________
1. Fit Pneutorque® with the correct size impact or high quality socket.
2. Ensure the clockwise/counter-clockwise selector is correctly set.
3. Rotate tool and reaction arm into a convenient position.
Fit the tool onto the fastener.
Locate reaction arm adjacent to the reaction point.
4. Adopt a suitable posture to counteract normal or
unexpected movement of the tool due to reaction forces.
5. Gently press Trigger to bring the reaction arm into contact with the reaction point.
6. Fully press 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.
7. Remove tool from fastener

PT72 SERIES OPERATORS HANDBOOK PAGE 10 OF 14
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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 BP
Energrease LS-EP1 or equivalent good quality grease.
SILENCER:- _________________________________________________________________
The silencer (#18266) 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 screw (B) (#25367.30) using a
3mm hexagonal key.
3. Pull out air inlet tube (D) with base plate &
silencer.
4. Remove silencer (E) from air inlet tube.
5. Fit new silencer (#18266) over air inlet tube.
6. Fit air inlet tube assembly (C, D & E) into
handle against spring resistance.
7. Fit screw (B) with a 3mm hexagonal key.
8. Fit screw (A) with a 2.5mm hexagonal key.
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 8

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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 9
The drive square can be replaced with either a ¾” drive square (#18221) or a 1” drive square (#18220). 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 8 N.m - 9 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.
DISPOSAL:- _________________________________________________________________
RECYCLING CONSIDERATIONS
COMPONENT MATERIAL
Handle Aluminium casting with epoxy finish.
Annulus Alloy steel with nickel plate finish.
Reaction plate Alloy steel with epoxy powder finish

PT72 SERIES OPERATORS HANDBOOK PAGE 12 OF 14
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SPECIFICATIONS
RANGE
MODEL N.m lbf.ft TOOL SPEED
(FREE RUNNING AT MAX. AIR
PRESSURE)
PT 72/500 90 – 500 N.m 66 – 370 lbf.ft 35 r/min
PT 72/500 Auto 2 speed 203 – 500 N.m 150 – 370 lbf.ft 170 r/min
PT 72/1000 190 – 1000 N.m 140 – 740 lbf.ft 15 r/min
PT 72/1000 Auto 2 speed 488 – 1000 N.m 360 – 740 lbf.ft 75 r/min
PT 72/1000 190 – 1000 N.m 140 – 740 lbf.ft 15 r/min
PT 72/1000 Auto 2 speed 488 – 1000 N.m 360 – 740 lbf.ft 75 r/min
PT 72/1500 300 – 1500 N.m 220 – 1110 lbf.ft 9 r/min
PT 72/1500 Auto 2 speed 760 – 1500 N.m 560 – 1110 lbf.ft 45 r/min
PT 72/2000 400 – 2000 N.m 300 – 1450 lbf.ft 6 r/min
PT 72/2000 Auto 2 speed 1000 – 2000 N.m 750 – 1450 lbf.ft 30 r/min
PT 4500 900 – 4500 N.m 660 – 3300 lbf.ft 4 r/min
PT 4500 Auto 2 speed 2400 – 4500 N.m 1750 – 3300 lbf.ft 13.5 r/min
Repeatability: ± 5%
Protractor increments 5° (where fitted)
Air Supply: Maximum pressure – 6.0 bar (For maximum torque capacity).
Air consumption – 11 litres / sec.
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.
MODEL TOOL WEIGHT REACTION WEIGHT DIMENSIONS
PT 72/**** 6.4 kg (14.1 lb) 1.7 kg (3.8 lb) 301mm x 72mm wide x 259mm
PT 72/**** Auto 2 speed 8.7 kg (19.2 lb) 1.7 kg (3.8 lb) 373mm x 72mm wide x 259mm
PT 4500 13.7 kg (30.2 lb) 4.0 kg (8.8 lb) 390mm x 140mm wide x 293mm
PT 4500 Auto 2 speed 16 kg (35.3 lb) 4.0 kg (8.8 lb) 462mm x 140mm wide x 293mm
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: 81 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 6.0 bar.
Environment: Indoor & dry outdoor use within a light industrial environment.
Due to continuous improvement all specifications are subject to change without prior notice.

PT72 SERIES OPERATORS HANDBOOK PAGE 13 OF 14
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Declaration of Conformity
Manufactured by Norbar Torque Tools Ltd.,
Beaumont Road, Banbury, Oxfordshire, OX16 1XJ
The Directives covered by this Declaration
Safety of Machinery Directive, 98/37/EEC
The Equipment Covered by this Declaration
Equipment: Pneutorque® PT 72mm Stall Tool.
Model Name(s): PT 72/500
PT 72/1000
PT 72/1500
PT 72/2000
PT 4500
Part Numbers: 18021.***, 18022.***, 18023.***, 18026.***, 18033.*** & 18038.***
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: 2002.
Signed: Full Name: Trevor Lester.
Date: 10th August 2005 Authority: Compliance Engineer

PT72 SERIES OPERATORS HANDBOOK PAGE 14 OF 14
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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.
AUT Auto Two speed.
Bi-directional Tool capable of Clockwise & Counter-clockwise square rotation.
CFM Cubic Feet per minute, measure of air flow.
BSP British Standard Pipe, this is a thread size.
Lubro Control Unit Unit to provide filtering and lubrication along with pressure regulation.
Not supplied with tool.
Pneutorque® Product name.
Reaction Arm Device to counteract applied torque.