norbar Handtorque HT 12, Handtorque HT 7, Handtorque HT 13, Handtorque HT 30, Handtorque HT 60 Operator's Manual

OPERATOR’S MANUAL

HANDTORQUETM MULTIPLIERS

Part Number 34269 | Issue 9 | Original Instructions (English/Deutsch)

1

CONTENTS

Part Numbers Covered by This Manual 2

Standard Series 2 Small Diameter Series 2 HT4 Series 2 Compact Series 2 Optional Extras 2

Safety 3

Introduction 3

Operating Instructions 4

Torque Reaction 5 Setting Torque for Bolt Tightening (Non-Calibrated) 8 Setting Torque for Bolt Tightening (Calibrated) 8 Setting Torque for Bolt Loosening 9 Operating the Multiplier 9

Anti Wind-Up Ratchet 10

Purpose of the Anti Wind-Up Ratchet 10 Operation of the Anti Wind-Up Ratchet 10

Maintenance 12

Output Square Drive 12 Cleaning 12

Specifications 13

Standard Series 13 Small Diameter Series 13 HT4 Series 14 Compact Series 14

Trouble Shooting 15

2

PART NUMBERS COVERED BY THIS MANUAL

This manual covers the setup and use of Norbar Handtorque

TM

multipliers.

Standard Series

Model

Maximum

Torque

Part Number

Without AWUR

With AWUR

HT 1 & HT 2

1700 N·m

16010, 16012, 16034

16089

HT 5 & HT 6

3400 N·m

16014, 16028, 16016, 16024

16090, 16092, 16093

HT 7

6000 N·m

16067, 16094, 16018

16065, 16095, 16068, 16096

HT 9

9500 N·m

16059

16070, 16071

HT 11

20000 N·m

16082

16049

HT 12

34000 N·m - 18082

HT 13

47500 N·m - 16053

Small Diameter Series

Model

Maximum

Torque

Part Number

Without AWUR

With AWUR

HT 30

3000 N·m

18003

18002, 18004, 18006

HT 60

6000 N·m

-

18008, 18010, 18012

HT4 Series

Model

Maximum

Torque

Part Number

Without AWUR

With AWUR

HT 4

3000 N·m

17022

-

HT 4

4500 N·m

17021

-

Compact Series

Model

Maximum

Torque

Part Number

Without AWUR

With AWUR

HT-52 & HT-72

1000 N·m

18087, 18051, 18052, 180200,

180201, 180202, 18014, 180207,

18018, 180211

18083, 18084, 180203, 180204, 18081, 18093,

18094, 180205, 180206

HT-72

1500 N·m

18015, 18016, 180208, 180209

-

HT-72

2000 N·m

18017, 18019, 180210, 180212

18082, 18095, 18096,

180213, 180214

HT-92

4000 N·m - 18092

HT-119

7000 N·m - 18091

HT-52 (HandtorqueTM Kit)

1000 N·m - 18196

HT-52 (HandtorqueTM Kit)

1000 N∙m - 18197

HT-72 (HandtorqueTM Kit)

2000 N·m - 18198

HT-92 (HandtorqueTM Kit)

4000 N·m - 18199

AWUR = Anti Wind Up Ratchet.

NOTE: For more information on HandtorqueTM Kits, see page 9.

Optional Extras

A range of Sockets, Nose Extensions and Annular Torque Transducers are available to suit the HandtorqueTM range.

3

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.

These tools require a reaction bar. See section on torque reaction.

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.

INTRODUCTION

The HandtorqueTM multiplier is a precision tool that will multiply the input torque by the specified ratio.

The HandtorqueTM multiplier is a planetary gear system. The outer case of the multiplier, known as the annulus, will rotate in the opposite direction to the input torque unless a reaction arm is fitted to the annulus. Without the reaction arm no torque is applied through the square drive. See section on torque reaction (Page

5) for more details.

HandtorqueTM multipliers with a high ratio gearbox (25:1 or more) require a certain amount of windup (backlash) to be taken up before any useful tightening work is applied to the nut. In this instance an Anti Wind-Up Ratchet (AWUR) is fitted to retain all of the wind up forces. See section on AWUR (Page 10 – 11) for more details.

4

REACTION PLATE

REACTION PLATE REACTION PLATE

REACTION PLATE

OPERATING INSTRUCTIONS

To operate the HandtorqueTM multiplier you will need the following:-

 Power Drive or Impact Quality Sockets.

 Reaction Arm.

 Norbar or other quality torque wrench.

Standard Series Small Diameter Series

HT4 Series Compact Series

FIGURE 1

INPUT SQUARE DRIVE

ANTI WIND-UP RATCHET

OUTPUT SQUARE DRIVE

SLAVE SQUARE

5

Torque Reaction

When the HandtorqueTM is in operation, the Reaction Plate rotates in the opposite direction to the Output Square Drive and must be allowed to rest squarely against a solid object or surface adjacent to the bolt to be tightened (see Figure 2).

Where the standard reaction plate is not suitable, it may be possible to adapt it. Refer to your Norbar distributor for advice.

Clockwise Operation Anti-Clockwise Operation

FIGURE 2

Reaction

Reaction Torque

Torque

6

IMPORTANT: CARE MUST BE TAKEN TO ENSURE THAT THE REACTION PLATE IS ONLY USED

WITHIN THE LIMITATIONS SHOWN IN FIGURES 3, 4, 5 AND 6.

For special applications or where extra deep sockets must be used the standard arm may be extended but only within the limitations shown in Figures 3, 4, 5 and 6.

WARNING: FAILURE TO OBSERVE THE LIMITATIONS SHOWN IN FIGURES 3, 4, 5

AND 6 WHEN MODIFYING STANDARD REACTION PLATES OR MAKING SPECIALS MAY RESULT IN PREMATURE WEAR OR DAMAGE TO THE MULTIPLIER OUTPUT DRIVE.

Standard square drive extensions MUST NOT be used as these will cause serious damage to the wrench output drive. Norbar manufacture a range of nose extensions for applications where access is restricted and these are designed to support the final drive correctly.

It is essential the reaction bar rests squarely against a solid object or surface adjacent to the fastener to be tightened, with reaction taken at the end of the reaction bar.

The supplied reaction bar has been designed to give an ideal reaction point when used with a standard length socket. If an extra long socket is used it may move the reaction bar outside the safe reaction window, as shown in figures 3, 4, 5 and 6. The standard reaction bar may need to be extended to ensure it remains wholly within the shaded area.

FIGURE 3 – Standard Series Safe Reaction Window

Torque Reaction should be

taken in the shaded areas only

Standard Length Socket

Extra Length Socket

FIGURE 4 – Small Diameter Series Safe Reaction Window

Torque Reaction should be

taken in the shaded areas only

Standard Length Socket

Extra Length Socket

7

FIGURE 5 – HT 4 Series Safe Reaction Window

Standard length Socket

Extra length Socket

Torque Reaction should be

taken in the shaded areas only

FIGURE 6 – Compact Series Safe Reaction Window

Standard Length Socket

Extra Length Socket

Torque Reaction should be

taken in the shaded areas only

8

FIGURE 7 – Certificate of Calibration

Supplied with Compact Series (see above

for applicable models).

24.21:1

Setting Torque for Bolt Tightening (Non-Calibrated)

1. Establish the correct torque figure for the bolt from manufacturer’s instructions or by calculation. A torque tension calculator is available on the Norbar website (www.norbar.com), which can be used as a guide to help calculate the tension generated in a bolt for a given thread size, torque and friction value.

NOTE: Many factors have an effect on the torque/induced load relationship and care should be

taken to consider factors such as surface finish and amount/type of lubrication. In critical applications, the relationship between torque and induced load should be determined by experimentation with the actual components and lubrication used.

2. Divide the required torque by the ‘Multiplication factor’ of the multiplier (See Specifications section, page

13). This gives the input torque.

Example: A HandtorqueTM HT 1 has a ‘Multiplication ratio of 5:1, so for an input torque of 1 N∙m there

is an output torque of 5 N∙m, with a +/- 4% tolerance.

To reach the HandtorqueTM HT 1 maximum output torque of 1,700 N∙m the below calculation is made:

1,700 (Required Torque)

=

340 N∙m (Input Torque)

5 (Multiplication Factor)

3. Select a suitable torque wrench for the input torque. The wrench should be of high quality and regularly calibrated.

Setting Torque for Bolt Tightening (Calibrated)

This section only applies to Handtorque’s that are supplied with a Certificate of Calibration (see Figure 7). The following part numbers come with a Certificate of Calibration; 18091, 18092, 18196, 18197, 18198, 18199, 180200, 180201, 180202, 180203, 180204, 180205, 180206, 180207, 180208, 180209,180210, 180211, 180212, 180213 and 180214.

1. Establish the correct torque figure for the bolt from manufacturer’s instructions or by calculation. A torque tension calculator is available on the Norbar website (www.norbar.com), which can be used as a guide to help calculate the tension generated in a bolt for a given thread size, torque and friction value.

NOTE: Many factors have an effect on the torque/induced load relationship and care should be

taken to consider factors such as surface finish and amount/type of lubrication. In critical applications, the relationship between torque and induced load should be determined by experimentation with the actual components and lubrication used.

2. Divide the required torque by the ‘Multiplication factor’ of the multiplier as stated on the Calibration Certificate included with the HandtorqueTM. This gives the input torque.

NOTE: Calibrated Handtorque’s come with a unique

Calibration Certificate which highlights the Handtorque’s unique ‘Multiplication Ratio. These Handtorque’s will have a slight variation in the gearbox ratio, so for more accurate results the ratio on the Calibration Certificate will need to be used.

Norbar multipliers are engineered such that each gear stage has a specific velocity ratio. For example; a 25:1 gearbox has 2 stages each with a velocity ratio of 5.45:1, giving an overall velocity ratio of

29.75:1. Taking the gearbox efficiency into account the

multiplication factor will give a ratio of around 25:1.

Torque output calculations are therefore a matter of simple arithmetic with little risk of incorrect bolt loading due to conversion errors. Other manufacturer’s multipliers often require graphs or formulae to calculate the input torque to achieve a particular output.

9

Example: The HandtorqueTM HT-92 Certificate of Calibration in Figure 7 displays a multiplication ratio of

24.21:1, meaning that for every 1 N∙m of input, 24.21 N∙m are output, with a +/- 4% tolerance.

To reach the HandtorqueTM HT-92 maximum output torque of 4,000 N∙m, the below calculation is made:

4,000 (Required Torque)

=

165 N∙m (Input Torque)

24.21 (Multiplication Factor)

3. Select a suitable torque wrench for the input torque. The wrench should be of high quality and regularly calibrated.

The HT 52, 72 and 92 Compact Series models can also come as part of a kit which includes a Norbar TTi Torque Wrench and Carry Case. The table below details the range of HandtorqueTM Kits available:

Kit Part

Number

Kit Contents

HandtorqueTM Multiplier

Torque Wrench

18184

HT-52 (18196)

TTi 45 lbf∙ft ONLY (13684)

18185

HT-52 (18196)

TTi 60 N∙m ONLY (13682)

18186

HT-52 (18196)

TTi 60 Dual Scale (13680)

18187

HT-52 (18197)

TTi 45 lbf∙ft ONLY (13684)

18188

HT-52 (18197)

TTi 60 N∙m ONLY (13682)

18189

HT-52 (18197)

TTi 60 Dual Scale (13680)

18190

HT-72 (18198)

TTi 75 lbf∙ft ONLY (13461)

18191

HT-72 (18198)

TTi 100 N∙m ONLY (13451)

18192

HT-72 (18198)

TTi 100 Dual Scale (13441)

18193

HT-92 (18199)

TTi 150 lbf∙ft ONLY (13463)

18194

HT-92 (18199)

TTi 200 N∙m ONLY (13453)

18195

HT-92 (18199)

TTi 200 Dual Scale (13443)

The HandtorqueTM Kit has a combined accuracy of +/- 6.5%. This is taken from a combination of the +/- 3% TTi Torque Wrench tolerance and the working variation of the HandtorqueTM gearbox.

NOTE: The accuracy of +/- 6.5% is only valid provided the multiplication ratio on the Calibration

Certificate is used and reaction is taken within the parameters demonstrated in Figure 6.

Setting Torque for Bolt Loosening

1. To ensure that the multiplier is not overloaded, it is desirable to use a torque wrench even for bolt loosening.

2. Divide the multiplier maximum output by the ‘Multiplication factor’. This gives the maximum input torque.

3. Select a suitable torque wrench for the input torque.

NOTE: Some torque wrenches will not be active (‘click’ or 'break') when used in the anti-clockwise

direction.

Operating the Multiplier

1. Fit the multiplier with the correct size of power drive or impact quality socket to suit the bolt to be tightened.

2. Fit the multiplier to the bolt with the reaction plate adjacent to the reaction point. See Figure 2.

3. Fit the torque wrench to the multiplier, set as in 'Setting Torque for Bolt Tightening'.

4. Operate the torque wrench in the normal manner until it 'clicks' or 'breaks'. Smooth and even use of the torque wrench will give more accurate results.

TIP: For extra accuracy a torque transducer can be used to measure the input or output torque.

10

ANTI WIND-UP RATCHET

Purpose of the Anti Wind-Up Ratchet (AWUR)

Most multipliers with ratios of 25:1 and over are fitted with an anti wind-up ratchet. The multiplier can be thought of as a spring which must be fully wound before any tightening/untightening work can be applied to the bolt.

The AWUR ensures that the 'spring' stays wound and that any further torque input to the multiplier is applied directly to the bolt.

Familiarise yourself with the tool by initially applying low torques and removing wind-up.

There are two different types of AWUR that your HandtorqueTM may be equipped with as demonstrated below in Figure 8. The AWUR shown on the left side of the page requires a hexagon key to lock in to the neutral position. The AWUR on the right side of the page will automatically lock into the neutral position without the need for a hexagon key.

Operation of the Anti Wind-Up Ratchet

Please Read Carefully

1. Position the ‘ratchet direction selector’ for the appropriate direction of operation:

Test direction of rotation and ensure that the ratchet operates freely.

Or CW = Clockwise

Or CCW = Anti-Clockwise

Or N = Neutral

WARNING: DO NOT USE TOOL IF RATCHET DOES NOT OPERATE FREELY.

Clockwise Operation / Bolt Tightening

Neutral Position:

Centralise the ‘ratchet direction selector’.

Depending on model type this may need locking

into position using a hexagon key. Check that the

input square rotates freely in both directions before

operation.

Anti-Clockwise Operation / Bolt Loosening

FIGURE 8

11

2. To apply torque, follow the instructions given earlier for setting and operating of the multiplier. Set the direction of operation for the Anti Wind-Up ratchet as shown in Figure 8.

3. To remove the multiplier, carefully load the gearbox until the ‘ratchet direction selector’ can be moved towards the neutral position. Allow the wrench to rotate slowly anti-clockwise until the multiplier becomes free.

3.1 Load the torque wrench.

FIGURE 9

3.2 With the wrench still loaded, move the ‘ratchet direction selector’ to anti-clockwise:

FIGURE 10

3.3 Allow the torque wrench to rotate slowly until the multiplier becomes free.

FIGURE 11

If wind-up cannot be released with one sweep of the wrench, re-engage the ratchet by pushing the ‘ratchet direction selector’ back to the clockwise position. Reposition the wrench and follow procedure 3 until the wind-up is fully released.

4. The tool may now be removed from the fastener.

5. Familiarise yourself with this tool by initially applying low torques and removing wind-up.

We recommend that the Anti Wind up assembly input gear and ratchet teeth are inspected annually by your Norbar approved distributor for wear or damage.

12

MAINTENANCE

Output Square Drive

The only user maintenance required on HandtorqueTM multipliers is the replacement of drive squares, should they become damaged. To avoid internal damage (especially due to torque overload), the output drive square / shaft have been designed to shear first. This saves major internal damage and allows easy square removal.

In some instances the square drive will not be removable without disassembling the gearbox. In these cases the HandtorqueTM multiplier should be returned to Norbar or a Norbar approved agent for repair.

However, in many cases the square drive can be replaced without disassembling the gearbox. In these cases remove the bolt holding the drive square in position (bolt will be either M4 or M5). Then remove the broken / damaged drive square. Fit the new drive square. Fit the new bolt and tighten (4.7 N·m for M4 bolts and 9 N·m for M5 bolts)

FIGURE 12

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.

Cleaning

Keep the tool in a clean condition to aid safety. Do not use abrasives or solvent based cleaners.

13

SPECIFICATIONS

Standard Series

Small Diameter Series

Model

Part

Number

Maximum Torque

Output

Ratio

Input

Square

Output

Square

N·m

lbf·ft

in

HT 30/5 AWUR

18002

3000

2200

5:1

¾”

1”

HT 30/5

18003

3000

2200

5:1

¾”

1”

HT 30/15 AWUR

18004

3000

2200

15:1

½”

1”

HT 30/25 AWUR

18006

3000

2200

25:1

½”

1”

HT 60/25 AWUR

18008

6000

4425

25:1

½”

1 ½”

HT 60/75 AWUR

18010

6000

4425

75:1

½”

1 ½”

HT 60/125 AWUR

18012

6000

4425

125:1

½”

1 ½”

Model

Part

Number

Maximum Torque

Output

Ratio

Input

Square

Output

Square

N·m

lbf·ft

In

in

HT 1/5

16010

1700

1250

5:1

½”

¾”

HT 2/5

16012

1700

1250

5:1

¾”

1”

HT 2/25

16034

1700

1250

25:1

¾”

1”

HT 2/25 AWUR

16089

1700

1250

25:1

¾”

1”

HT 5/5

16014

3400

2500

5:1

¾”

1”

HT 5/25

16028

3400

2500

25:1

½”

1”

HT 5/25 AWUR

16090

3400

2500

25:1

½”

1”

HT 6/5

16016

3400

2500

5:1

¾”

1 ½”

HT 6/25

16024

3400

2500

25:1

½”

1 ½”

HT 6/25 AWUR

16092

3400

2500

25:1

½”

1 ½”

HT 6/125 AWUR

16093

3400

2500

125:1

½”

1 ½”

HT 7/5

16067

6000

4425

5:1

¾”

1 ½”

HT 7/5

16094

6000

4425

5:1

½”

1 ½”

HT 7/25

16018

6000

4425

25:1

½”

1 ½”

HT 7/25 AWUR

16065

6000

4425

25:1

½”

1 ½”

HT 7/25 Small

Diameter AWUR

16095

6000

4425

25:1

½”

1 ½”

HT 7/125

16068

6000

4425

125:1

½”

1 ½”

HT 7/125 Small

Diameter AWUR

16096

6000

4425

125:1

½”

1 ½”

HT 9/25

16059

9500

7000

25:1

¾”

1 ½”

HT 9/25 AWUR

16070

9500

7000

25:1

¾”

1 ½”

HT 9/125 AWUR

16071

9500

7000

125:1

½”

1 ½”

HT 11/25

16082

20000

14700

25:1

¾”

2 ½”

HT 11/125 AWUR

16049

20000

14700

125:1

½”

2 ½”

HT 12/87.5 AWUR

18085

34000

25000

87.5:1

¾”

2 ½”

HT 13/125 AWUR

16053

47500

35000

125:1

¾”

2 ½”

14

HT4 Series

Model

Part

Number

Maximum Torque Output

Ratio

Input Square

Output Square

N·m

lbf·ft

in

HT4/15.5

17022

3000

2200

15.5:1

½”

1”

HT4/26

17021

4500

3300

26:1

½”

1”

Compact Series

Model

Part

Number

Maximum Torque Output

Ratio

Input Square

Output Square

N·m

lbf·ft

in

In

HT-52/4.5

18087

1000

740

4.5:1

½”

¾”

HT-52/4.5

180200

1000

740

4.5:1

½”

¾”

HT-52/22

18051

1000

740

22:1

⅜”

¾”

HT-52/22

180201

1000

740

22:1

⅜”

¾”

HT-52/22

18052

1000

740

22:1

½”

¾”

HT-52/22

180202

1000

740

22:1

½”

¾”

HT-52/22 AWUR

18083

1000

740

22:1

⅜”

¾”

HT-52/22 AWUR

180203

1000

740

22:1

⅜”

¾”

HT-52/22 AWUR

18084

1000

740

22:1

½”

¾”

HT-52/22 AWUR

180204

1000

740

22:1

½”

¾”

HT-52/22 AWUR

18093

1000

740

22:1

⅜”

1”

HT-52/22 AWUR

180205

1000

740

22:1

⅜”

1”

HT-52/22 AWUR

18094

1000

740

22:1

½”

1”

HT-52/22 AWUR

180206

1000

740

22:1

½”

1”

HT-72/5

18014

1000

740

5:1

½”

¾”

HT-72/5

180207

1000

740

5:1

½”

¾”

HT-72/5

18015

1500

1100

5:1

½”

1”

HT-72/5

180208

1500

1100

5:1

½”

1”

HT-72/5

18016

1500

1100

5:1

¾”

HT-72/5

180209

1500

1100

5:1

¾”

HT-72/5

18017

2000

1450

5:1

¾”

1”

HT-72/5

180210

2000

1450

5:1

¾”

1”

HT-72/25

18018

1000

740

25:1

½”

¾”

HT-72/27

180211

1000

740

27:1

½”

¾”

HT-72/25

18019

2000

1450

25:1

½”

1”

HT-72/27

180212

2000

1450

27:1

½”

1”

HT-72/25 AWUR

18081

1000

740

25:1

½”

¾”

HT-72/25 AWUR

18082

2000

1450

25:1

½”

1”

HT-72/27 AWUR

180213

2000

1450

27:1

½”

¾”

HT-72/27 AWUR

180214

2000

1450

27:1

½”

1”

HT-92/25 AWUR

18092

4000

2950

25:1

½”

1”

HT-119/25 AWUR

18091

7000

5100

25:1

½”

1 ½”

HT-52 (HandtorqueTM Kit)

18196

1000

740

22:1

½”

¾”

HT-52 (HandtorqueTM Kit)

18197

1000

740

22:1

½”

1”

HT-72 (HandtorqueTM Kit)

18198

2000

1450

27:1

½”

1”

HT-92 (HandtorqueTM Kit)

18199

4000

2950

25:1

½”

1”

NOTE: Some of the ratios in the above table are a rough guide only, for more accurate results

please refer to the multiplication ratio on your Certificate of Calibration provided with your HandtorqueTM (see page 8).

15

TROUBLE SHOOTING

The following is only a guide, for more complex faults please contact your local Norbar agent or Norbar directly.

Problem

Likely Solutions

Drive square sheared

See maintenance section.

Input drive rotates but output will not

Serious damage to internal gears, return to Norbar or agent for repair (Check AWUR change lever is not in neutral position).

Input drive will not rotate

Check AWUR change lever is in the correct position.

OPERATOR’S MANUAL

HANDTORQUETM MULTIPLIERS

Part Number 34269 | Issue 9 | Original Instructions (English/Deutsch)

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