FlexArm GH-24 User manual
1/26/2021 REV. 007 2
TABLE OF CONTENTS:
Safe Operation: READ THIS FIRST - - - - - - - - - - - - - - - - - - - -
3
Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
4
Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
5-6
Electrical Installation - - - -- - - - - - - - - - - - - - - - - - - - - - - - - -
7
Arm Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
8-10
Start Up Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
11
Shut Down Procedure - - - - - - - - - - - - - - - - - - - - - - - - - - - -
13
Tap Lubricator System - - - - - - - - - - - - - - - - - - - - - - - - - - - -
14
Operator Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
15
Adjusting Torque Holder Clutch Setting - - - - - - - - - - - - - - -
16
Torque Requirements for Tapping - - - - - - - - - - - - - - - - - - -
17
Multi-Position Head Operating Instructions - - - - - - - - - - - -
18-19
Counterbalance Adjustment - - - - - - - - - - - - - - - - - - - - - - -
20
Parts Breakdown: ARMS - - - - - - - - - - - - - - - - - - - - - - - - - -
21-29
Parts Breakdown: 2-SPEED GEARBOX - - - - - - - - - - - - - - - - -
30-31
Parts Breakdown: ACCESORIES - - - - - - - - - - - - - - - - - - - - - -
32-36
Parts Breakdown: POWER PACK - - - - - - - - - - - - - - - - - - - - -
37-42
Cylinder Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - -
44-47
Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
48-50
Troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
51-54
1/26/2021 REV. 007 3
SAFE OPERATION: READ THIS FIRST
•Read the entire unit manual before operating the machine.
•Do not remove shipping zip tie strap until instructed in this manual.
•Wear eye protection when operating this machine.
•Do not wear jewelry when operating this machine. Tie hair back when using this machine.
•Do not wear gloves when operating this machine.
•Turn off the air supply before adding oil to the filter / lubricator.
•Turn off the air supply before preforming any maintenance operations.
•Hearing Protection is recommended.
•Removing the tool or weight from the arm will allow the arms to extend rapidly possibly causing
damage or injury.
•Keep hands clear of the motor chuck and tap when the motor is running.
•Keep hands clear of pinch points when operating the machine.
•Do not alter or modify the FlexArm.
•Periodically inspect for damage, loose hardware or anything irregular on the FlexArm.
•Preform regular maintenance according to this manual.
•Do not alter or modify the machine.
•Read the FlexArm Limited Warranty before performing any maintenance or repairs.
•FlexArm is not responsible for accident or injury resulting from the misuse of this machine or for use
other than originally designed and intended.
IT IS IMPERATIVE THAT THE TABLE OR MOUNTING SURFACE BE LAGGED TO THE FLOOR AND SECURE BEFORE
INSTALLING THE FLEXARM. Failure to secure the table or mounting surface could result in serious injury to the
operator as well as the FlexArm.
•The oil hoses & fittings are rated for a maximum operating pressure of 180 Bar.
•The normal operating pressure of the unit is between 100 and 120 Bar.
•The workpieces must be firmly held in place to avoid breakage of taps or to strike the operator. The
operator doesn't have to wear special clothing, but protection glasses must be worn.
•When the machine is installed, connect it to the ground clamp system before operating.
•For every adjustment to this machine, the master switch must be disconnected, and the work carried
out by licensed electricians.
1/26/2021 REV. 007 4
FLEXARM LIMITED WARRANTY
What does a FlexArm Warranty Cover
The repair or replacement of the FlexArm product if it is found to be defective due to faulty materials,
workmanship or function within the guarantee period of 1 year. The warranty is based off normal
usage, or equivalent to a 40-hour work week. Claims within the first 90 days will be handled under a
direct return and replace policy. Freight can be credited up to $500.00 upon a positive warranty claim.
What is not covered by a FlexArm Warranty
FlexArm Inc shall not be liable for costs of repair or replacement of a product incurred as a result of:
•A FlexArm product that has had the serial number altered or removed.
•Cylinders with scratches or marks on the shaft.
•Handling of the product which is not in accordance with the product manual.
•Damage as a result of using the unit over its stated capacities.
•FlexArm products not purchased direct or from an authorized dealer.
•Use of parts and accessories other than those produced or recommended by FlexArm.
•Improper maintenance or lack of maintenance per the manual.
•Damage from external sources such as transit, weather, electrical outages, power surges, or bad
air quality (compressor).
•Repairs or alterations carried out by parties other than FlexArm or its authorized distributors.
•Tap Holders and Helicoil components do not carry a warranty.
In Air Motors: Filters, Springs, Blades/Vanes, O-Rings are not covered.
Warranty Service
Before service can take place, the terms of the limited warranty require that you contact FlexArm with
your model, serial number, and date of purchase. Please keep your purchase receipt in a safe place to
ensure you have this information. The serial number is found on the FlexArm’s side plate.
•An RGA must be obtained from a FlexArm Customer Service Representative.
•All work will be coordinated by FlexArm or its authorized distributors.
•Any replaced defective parts must/will become the property of FlexArm.
Service under this warranty will not extend the period of this warranty. If your FlexArm is not
functioning properly, please call FlexArm at 1-800-837-2503. Most issues can be rectified over the
telephone by our trained Customer Service Department.
1/26/2021 REV. 007 5
SPECIFICATIONS
TECHNICAL DETAILS CHART
MODEL
GH-24
GH-30
GH-45
GH-60
Electric Motor (HP)
5.5
5.5
5.5
5.5
Operating Pressure (Bar)
120
120
120
120
Min Thread Capacity
#6
#6
1/4"
1/4"
Max Thread Capacity
7/8"
1-1/4"
1-1/2"
2"
RPM
100-500
140-500
110-500
55-275
Oil Tank Capacity (Gallons)
9
9
9
9
Max Torque (lbf-ft)
78/63
188/63
325/63
811/162
1/26/2021 REV. 007 6
SPECIFICATIONS
Hydraulic Oil:
•This unit has been factory tested and ships with hydraulic oil in the tank. The tank holds a maximum of
9 gallons of hydraulic oil. Check the oil level on the oil level/temperature gauge on the front of the
power pack.
•The following (ISO Grade 46 compatible) hydraulic oils are recommended for use in the FlexArmTM
Hydraulic Tapping Machines:
Hydraulic Oils
Brand Name
Manufacturer
Energol HLP-46
BP
DTE 25
Exxon Mobil
NUTO HP 46
Exxon Mobil
Tellus 46
Shell Oil Corporation
Hyspin AWS 46
Castrol
Rando HD ISO 46
Chevron
WARNING!
Do not operate the machine if the oil level is BELOW the RED DOTTED LINES on the oil level gauge.
Do not add oil while the machine is operating. First, turn off the machine, disconnect the power supply, and
allow the unit to cool down to 80 degrees or less before adding hydraulic oil.
To add oil, unscrew the cap on the oil tank at the back of the power pack. Using a funnel with a flexible spout,
pour the oil slowly into the tank and check the oil level/temperature gauge as it is being added. DO NOT FILL
ABOVE THE BLACK DOTTED LINES AT THE TOP OF THE OIL LEVEVTEMPERATURE GAUGE.
1/26/2021 REV. 007 7
ELECTRICAL INSTALLATION
1. Check the voltage your unit is wired for, either 220V or 480V. This will be indicated on the electrical panel
on the rear of the Power Pack unit. An example of a 480V unit is shown below, with the voltage sticker
next to the master switch.
2. Connect the machine to a grounded, 3 phase electric supply. The circuit should be protected with a 20
amp circuit breaker if it is wired for 480v and 30 amps if it is wired for 220v. The unit does not come with a
plug.
CAUTION: When making repairs to this unit, always disconnect the main power supply. Additionally,
hooking up an incorrect power supply could result in damage to the unit and void any existing warranty.
1/26/2021 REV. 007 8
ARM INSTALLATION
1. Drill and tap four bolt holes on a flat, smooth table or workbench. Use 3/8-16 bolts for the 24, 30, and
45 series units. Use 1/2-13 bolts on the 60 series units. (See Base Mount diagram below)
Base Mount Patterns
GH-24, GHM-24, GH-30
GHM-30, GH-45, GHM-45
GH-60, GHM-60
2. Secure the base mount and apply a light coating of grease to the base mount shaft. Slide the angle
mount onto the shaft of the base mount and secure the angle before inserting the FlexArmTM! (See
Angle Mount Assembly Diagram Below)
1/26/2021 REV. 007 9
ARM INSTALLATION
3. Secure the angle mount by placing the washer on top of the lower bore and tightening the angle
mount bolt securely into the base mount for a GH-24 and GH-30. For the GH-45 and GH-60, tighten the
two angle mount screws. The angle mount bolts must be tightened securely, or the machine will not
maintain perpendicularity.
4. Insert the rear pin of the unit into the upper bore and bearing of the angle mount. The rear pin may
not slide through both bearing sets- use the flathead cap screw to help pull the unit entirely through
the bottom bearing
5. Remove any straps holding the arms together and adjust the counterbalance of the arm. This will
eliminate the possibility of the arm striking the operator when it is positioned at its lowest point. (See
Counter Balance Adjustment Section on page 21)
1/26/2021 REV. 007 10
ARM TO POWER PACK INSTALLATION
1. After the FlexArm is securely fastened to its mounting surface, it can be hooked up to the power pack.
2. First, connect the two hydraulic hoses on the arm to the quick-disconnect hose couplings on the power
pack. There should be a male and female fitting.
3. Next, attach the male four-pin connector on the arm to the left female receptacle on the power pack.
There should be a locking clip on the female receptacle, notating the proper one to attach to.
4. The four-pin female connecter on the right is only to be used with arms adapted with digital depth
control (Instructions for digital depth control are found in a separate manual).
5. Lastly, the airline can be connected to the regulator-manometer shown on the far left of the image
below. This is to be used with units that have the semi-tap lubricator option.
1/26/2021 REV. 007 11
START UP PROCEDURE
1. Plug the unit into the power source.
2. Turn on the red master lock out switch on the rear of the Power Pack unit.
3. Ensure the emergency stop on front of the unit is pulled out and not engaged.
4. Pull out the front HMI display and wait for it to boot up. It should display as shown below:
5. To run the motor, press the green start button.
6. Next, you need to confirm you are in the proper gear setting on both the arm's gearbox and the
display. The image next image on the following page shows gear 2 selected on the HMI.
000
Validation
Speed
Enter
1
2
Start
Stop
1/26/2021 REV. 007 12
7. Once you confirm the gear settings match, press validation and you can begin tapping.
8. When switching gears, once again validate you are in the proper gear setting on both the arm's
gearbox and the display. You will need to re-press the validation button before you begin tapping
again.
500
Validation
Speed
Enter
1
2
Start
Stop
100
Validation
Speed
Enter
1
2
Start
Stop
1/26/2021 REV. 007 13
SHUT DOWN PROCEDURE
1. Press the red stop button on the HMI to simply turn the motor off if it doesn't need to be used for a
short period of time.
a. If the unit is left on for a short period of time without being used, it will enter sleep mode and
turn off by itself.
2. The master switch only needs to be switched off if the unit will not be used for a more extended period
of time.
a. Before turning off the master switch, press the red stop button on the HMI and allow the motor
in the power pack to completely spool down before continuing.
IMPROPER SHUTDOWN
●Turning the machine off with the master switch before turning off the machine with the red button.
●Turning the master switch off before the motor in the power pack has spooled down completely.
(approximately 3 seconds)
●Suddenly removing power from the machine, i.e., pulling the plug out of the wall before turning off the
device with the red button.
●Unplugging the unit before the motor in the power pack has spooled down completely. (approximately
3 seconds)
●Pressing the green button while the master switch is off and residual power is still in the inverter
(approximately 45 seconds after shutdown)
IF IMPROPER SHUTDOWN OCCURS
1. Reset the power pack by turning the master switch off.
2. Unplug the machine (wait 45 seconds to allow the inverter to reboot)
3. Plug the machine back in
4. Re-follow the steps in the startup procedure.
1/26/2021 REV. 007 14
TAP LUBRICATOR SYSTEM
FlexArm includes a standard tap lubricator system on its tapping units. [Refer to diagram]
●Ensure the air inlet and the arm's air tube are connected to the regulator-manometer, adjusted in our
factory.
●Fill oil tank located in the front lower arm: uncover the filler plug and fill with tapping oil to the maximum
level.
●Press and hold the starting lever until you see atomized oil begin to leave for the lance tip. The first time,
the atomized oil will take time to reach the lance tip, but later will be much quicker.
●Adjust the quantity of oil mixture released by adjusting the oil regulator mounted behind the lance.
●The tap lubricator system can be used before, during, and after tapping pieces.
Caution! Don't use corrosive oil. It can damage the system's plastic valves.
1/26/2021 REV. 007 15
OPERATING INSTRUCTIONS:
1. Ensure the part to be tapped is secured and sitting flat on
the same flat surface as the tapping arm is mounted.
2. Select the correct tap holder for the tap size required.
Insert the tap into the holder by depressing the locking
ring. Seat the tap square into the tap holder. Release the
locking ring (see Figure 1).
3. Push up the quick-change chuck’s collar to insert the tap holder.
When inserting the tap holder in the quick-change chuck, turn the
holder to align the ears of the holder to the drive slots in the quick-
change chuck. Push up to lock the holder in the chuck (see Figure 2).
4. Position the tap over the hole to be tapped.
5. When tapping through holes, remember that the tap will protrude
through the bottom side of the work piece. Ensure there is sufficient
clearance below the workpiece to allow the tap to extend below the
bottom surface of the part and not hit the work surface.
6. Use a torque style tap holder when tapping blind or bottom holes.
The built in safety clutch on the torque holders will rachet and stop the tap from turning when the tap
reaches the bottom of the hole.
7. Actuate the motor by depressing the lower button and gently guide the tap into the hole. Exert only
enough downward pressure to start the tap in the hole. Once started, the tap pull itself through the
hole.
Do not push or pull on the motor when the tap is engaged in the hole and completing the tapping
process. This will result in poor thread quality, oversized threads, and broken taps.
8. When the hole is tapped (the torque holder rachets for blind holes or the tap extends past the bottom
of through holes) release the lower button and depress the upper button to reverse the rotation of the
motor and remove the tap from the hole.
9. To change tap holders, release the tap holder by pulling up on the quick-change chuck collar and
pulling the tap holder out of the quick-change chuck.
Figure 2
Figure 1
1/26/2021 REV. 007 16
ADJUSTING TORQUE HOLDER CLUTCH SETTING:
The torque holders are factory preset to the standard break torque limits developed for each tap size in mild
steel (approximately 229 BHN or 25 RC). The break torque limit protects the tap when tapping blind or bottom
holes. When the tap reaches the bottom of the hole, resistance will cause the torque holder’s safety clutch to
ratchet and stop the tap from turning, over-torqueing and ultimately breaking. When tapping hardened steel
(above 40 RC), stainless steel, or other tough alloys, an increase in the factory torque setting may be required
in order to drive the tap the full depth of the hole. When using the torque adapters to tap soft materials or
plastics, a decrease in the factory torque setting prevents the tap from over-torqueing after it reaches the
bottom of the hole (See “Torque Requirements for Tapping” chart on the following page).
There are two locking holes on the outside diameter of the torque holder that the tail of the snap ring aligns
to. These two positions allow the holder to be adjusted one half of a full notch of the adjustable thread ring at
a time. The tail of the snap ring must be inserted in the hole at either position and through a notch of the
thread ring in order to lock the adjusted torque setting. Figure 3 below shows the components related to the
adjustment of the torque holder.
Caution: Never adjust the torque setting more than one (1) notch at a time. Adverse tapping conditions and
broken taps may result!
To adjust the torque setting, first
remove the tap, then remove the
snap ring as shown in figure 4.
Take note of the hole location in
which the tail of the snap ring was
removed. Use the spanner wrench
to turn the torque adjustment ring
either clockwise to increase the torque setting, or counter-clockwise to reduce the torque setting.
After turning the thread ring a full notch, reinsert the tail of the snap ring in the original hole. If a lesser
adjustment is needed, turn the adjusting thread ring half the distance between the thread ring notches. Insert
the snap ring tail in the alternate hole on the outside diameter of the torque holder. This hole will be aligned
with a notch of the adjusting ring.
Figure 3
Figure 4
1/26/2021 REV. 007 17
TORQUE REQUIREMENTS FOR TAPPING:
Tap Size Brass
(in/lbs)
Aluminum and
leaded brass
(in/lbs)
200 BHN
Steel
(in/lbs)
300 BHN
Steel
(in/lbs)
400 BHN
Steel
(in/lbs)
Approx.
Break Torque
(in/lbs)
Torque Holder
Factory Setting
(in/lbs)
#6
4
2
7
9
10
18
15
#8
4.5
2.25
8
10
11
30
17
#10
8.5
4.25
15
19
21
42
31
1/4
16
8
28
36
40
106
70
5/16
24
12
42
54
60
180
100
3/8
37
18.5
65
83
93
240
150
7/16
54
27
94.5
122
135
500
250
1/2
68
34
119
153
170
700
300
9/16
88
44
154
198
220
850
350
5/8
119
59.5
208
268
298
1,000
400
3/4
170
85
298
383
425
1,500
620
7/8
238
119
416
536
595
2,100
880
1
337
168.5
590
758
842
2,700
1,200
1-1/4
554
277
970
1,246
1,385
3,000+
2,100
1-1/2
850
425
1,488
1,912
2,125
3,100
1-3/4
1,411
706
2,471
3,177
3,530
5,500
2
1,904
952
3,332
4,284
4,760
7,000
1/26/2021 REV. 007 18
MULTI-POSITION HEAD OPREATING INSTRUCTIONS
Please follow the steps below to switch from vertical tapping to horizontal tapping.
1. Items needed:
a. Adjustable wrench and or socket.
b. Metric Allen wrench set
c. Magnetic plug
d. NOTE: The GHM-24 has handles instead of bolts, so no tools
are needed.
2. Insert the magnetic plug into the chuck (Figure 5).
3. Next, you will need an adjustable wrench or socket and a metric
Allen wrench to loosen the two bolts on the side plates and move
the head down into horizontal orientation (Figure 6).
4. Leave these bolts on the side plates loose.
5. When the head is used, as shown in figure 6 and 7,
you will need to break loose the hex head bolt on
top. A wrench or socket will be required for this.
6. With both rotations now free, align the magnetic
plug to the horizontal work surface (Figure 7).
Once the magnetic plug is locked on to the
horizontal surface, the side plates' bolts can be
tightened entirely down.
Figure 5
Figure 6
Figure 7
1/26/2021 REV. 007 19
7. The top bolt needs to be kept loose when tapping in the horizontal orientation.
8. Now that the unit is aligned, the magnetic plug can be removed, and the desired tap can be inserted
into the chuck. The unit is now ready to be used for horizontal tapping.
9. To get back to vertical tapping, remove the tap and reinsert the magnetic plug.
10. Loosen the bolts on the side plates, and the top
bolt should already be loose and realign the
magnetic plug to the vertical surface (Figure 8).
11. Completely tighten down the two side plate
bolts and the top bolt, which is now between
the side plates facing the rear.
12. Remove the plug and reinsert the right tap and
begin tapping.
Figure 8
1/26/2021 REV. 007 20
COUNTERBALANCE ADJUSTMENT
Both the front and rear arms can be adjusted to meet the operator preference.
To adjust the counterbalance, turn the adjuster screw located between the top plates for the front arms, and
the adjuster screw located between the rear plates for the rear arms in the image below. This will move the
cylinder clevis up or down.
•To decrease the counterbalance force applied by the gas cylinders, turn the adjuster clockwise. This
will move cylinder clevis up.
•To increase the counterbalance force applied by the gas cylinders, turn the adjuster counter-clockwise.
This will move the cylinder clevis down.
•The GH-60 & GHM-60 have no bottom handle; use a wrench to turn the adjusting bolt.
•Note: Extending the arms will make it easier to turn the adjuster handles.
Other manuals for GH-24
1
This manual suits for next models
7
Table of contents
Other FlexArm Industrial Equipment manuals
