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
ISSUE 1
08 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 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
ISSUE 1
08 2005
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.

PT72 SERIES OPERATORS HANDBOOK PAGE 4 OF 14
ISSUE 1
08 2005
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.)

PT72 SERIES OPERATORS HANDBOOK PAGE 5 OF 14
ISSUE 1
08 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 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

PT72 SERIES OPERATORS HANDBOOK PAGE 6 OF 14
ISSUE 1
08 2005
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
ISSUE 1
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
ISSUE 1
08 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.
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.