FlexArm S-36 User manual
10/29/2020 REV. 003 2
TABLE OF CONTENTS:
Safe Operation: READ THIS FIRST - - - - - - - - - - - - - - - - - - - -
3
Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
4
Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
5-7
Counterbalance Adjustments - - - - - - - - - - - - - - - - - - - - - - -
8
Operating Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - -
9-10
Adjusting Torque Holder Clutch Setting - - - - - - - - - - - - - - -
11
Torque Requirements for Tapping Chart - - - - - - - - - - - - - - -
12
Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
13-14
Drawing: S-36 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
15
Drawing: M-60 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
16
Cylinder Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - -
17-19
Parts and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
20-27
Troubleshooting - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - -
28-30
10/29/2020 REV. 003 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.
10/29/2020 REV. 003 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.
10/29/2020 REV. 003 5
INSTALLATION
1. Drill four bolt holes on a flat, smooth table or
work bench in the pattern shown in Figure 1.
2. Make sure the table the arm is being installed on
is secure, and will not tip over if the arm extended
off the side of the table.
3. Fasten the FlexArm base mount to the table and secure it with 3/8” bolts as shown in Figure 2.
4. Slide the angle mount over the shaft of the base mount as shown in Figure 3.
5. Secure the angle mount by placing the washer on top of the lower bore and tighten the angle bolt
securely into the base mount. If this bolt in not properly tightened and the angle mount is not secure,
the perpendicularity could be offset.
Figure 3
Figure 1
Figure 2
10/29/2020 REV. 003 6
6. Slide the rear pin of the FlexArm into the upper
bore of the angle mount as shown in Figure 4.
Note: Use caution not to damage the two roller
bearings in the upper bore of the angle mount.
7. Install the unit’s airline into the press-to-
release airline fitting (see Figure 4).
8. Cut and remove the shipping zip tie strap (see
Figure 4).
9. Install a ¼” NPT fitting into the incoming air
port on the unit’s filter / lubricator (see Figure
4). The supply airline should have a minimum
½” I.D. The unit must have a proper air supply
(90 – 120 psi and 27-28 cfm) at the motor to
generate the torque required to drive the
maximum tap capacity for this unit.
10. Fill the lubricator bowl approximately ¾ full by removing the black fill plug on the top of the lubricator
and pouring oil into the fill port. Use only a quality ISO Grade 32 hydraulic or spindle oil. Never use
Marvel Mystery Oil, synthetic air tool oil, or
similar products.
11. With the motor running, slowly adjust the
lubricator adjustment knob (see Figure 5) so 1-3
drops of oil are dispensed per minute. The site
glass to see the drops is located in the
adjustment knob. Clockwise decreases the flow,
counter-clockwise increases it. NOTE: It may be necessary
to open the adjustment knob considerably before the oil starts to drip. Once oil starts to drip, slowly
close the adjustment knob to achieve the target drip rate of 1-3 drops per minute.
Figure 4
Figure 5
10/29/2020 REV. 003 7
12. The filter is equipped with an auto drain and will automatically remove water from the filter bowl.
13. Check the counterbalance of the unit.
a. The unit comes counterbalanced to factory specifications.
b. The counterbalance can be adjusted to meet the operator’s preference.
14. To adjust the counterbalance, refer to the counterbalance adjustment page of this manual.
15. The unit is now ready for use.
10/29/2020 REV. 003 8
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 (see Figure 6). This will move the dowel
pin up or down in the side plates slot.
1. To decrease the counterbalance force applied by
the gas cylinders, turn the hex of the
adjuster screw clockwise with a
3/16” Allen wrench. This will
move the dowel pin towards
the top of the side plate slot.
2. To increase the counterbalance
force applied by the gas
cylinders, turn the hex of the
adjuster screw counter-clockwise
with a 3/16” Allen wrench.
This will move the dowel pin
towards the bottom of the
side plates slot.
Figure 6
10/29/2020 REV. 003 9
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 7).
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 8).
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 throttle lever 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.
Figure 7
Figure 8
10/29/2020 REV. 003 10
8. When the hole is tapped (the torque holder rachets for blind holes or the tap extends past the bottom
of through holes) actuate the throttle lever and reverse button at the same time 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.
10/29/2020 REV. 003 11
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 9 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 10.
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 9
Figure 10
10/29/2020 REV. 003 12
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
10/29/2020 REV. 003 13
MAINTENANCE:
•Oiling the Motor:
If the FlexArm has been sitting a while between jobs, it may be necessary to add 4-5 drips of oil directly
into the motor inlet to place oil on the vanes before running. It will take the lubricator a short time to
actually get the oil to the motor when first running the unit. The lubricator must be checked periodically to
ensure that the flow rate of 1-3 drops per minute is maintained.
•Cleaning the FlexArm:
The FlexArm should be periodically cleaned and free of dirt, debris, grinding dust, etc. An airline can be
used to blow the dust and chips away from the arms, arm joints, motor, chuck, etc. Never use oil, WD-40,
or any other lubricant to lubricate the arm joints (arm joints are constructed with self-lubricating bushings
and require no maintenance). Never use harsh cleaners or solvents. Never allow any cleaning agent to
reach the arm joints.
•Base Mount:
If it is necessary to remove the unit from the base, do not allow the shaft or the needle bearings to be
contaminated by dirt or foreign materials. If the shaft or base mount needle bearings become
contaminated, they must be thoroughly cleaned prior to re-assembly. To clean the base mount needle
bearings, the entire base mount angle must be removed and cleaned in a parts cleaner or cleaning tank to
remove the contamination from the bearings. The bearings should be submersed and a brush used to
remove the contamination as well as any residual grease. Apply a quality NLGI #2 grade GC-LB lithium
complex EP grease to the rollers of the bearings prior to re-assembly.
•Periodically check the bolts throughout the unit for tightness:
If the bolts have loosened up, use Loctite 242 (blue) on the threads and reassemble. This should prevent
any further problems.
•Filter / Lubricator:
Check that the filter/lubricator is set for approximately 1-3 drops per minute as indicated in the
INSTALLATION of this manual. Always use 10 wt. hydraulic oil or light spindle oil. (EP-32 hydraulic oil is
recommended). Never use Marvel Mystery Oil or synthetic products. Make sure to clean the filter and
drain excess water from the filter bowl on a regular basis.
•Motors with a quick-change chuck:
Keep both the motor and the chuck free from contamination by cleaning regularly: An airline can be used
to blow dust, dirt, and debris off of the motor and chuck collar. Make sure to clean inner surface of the
chuck as well. If contaminants build up too excessively, it may become necessary to soak the entire chuck
in cleaning solvent or WD-40 type penetrating oil before using the airline. Doing this regularly will
10/29/2020 REV. 003 14
considerably reduce, and may even eliminate, the need to disassemble the quick-change chuck to clean it.
If, however, the chuck has accumulated so much dirt and grime that disassembly is necessary, follow the
procedures given below:
oQuick Change Chuck with Knurled Collar:
Lift the snap ring out of the groove and slide it towards the motor, resting on the chuck body. The
collar can then slide along the chuck body, exposing the compression spring and the two ball
bearings. (CAUTION: The ball bearings are held in place only by the collar; be careful not to lose
these ball bearings!) Clean the exposed area of the chuck body, the spring, and the two ball
bearings and reassemble the chuck. Use the spring to hold one of the ball bearings in place,
position the other ball bearing, and slide the collar back into position (it may be necessary to
depress the ejector in the center of the chuck body to completely slide the collar back into place.)
Replace the snap ring in the groove on the chuck body.
oQuick Change Chuck with Smooth Collar:
Slide the collar upward until it locks into the upper most position. The snap ring is located between
the chuck body and the collar (on the open end where the tap holders inserted). Use an awl or
small slotted screwdriver to locate one of the snap ring ends. Rotate the snap ring end until it is
positioned in one of the two chuck slots. It can now be carefully lifted upward and by using a
circular motion, the ring can be completely removed. The collar can now be removed by depressing
the ejector in the center of the chuck body (CAUTION: The collar may eject rapidly. Be careful not
to damage the collar or lose the ball bearings, spring, or snap ring). Clean the exposed area of the
chuck and reassemble (It may be necessary to depress the ejector in the center of the chuck body
to completely slide the collar back into place). Replace the snap ring in the groove on the chuck
body.
10/29/2020 REV. 003 15
DRAWING: S-36
10/29/2020 REV. 003 16
DRAWING: M-60
10/29/2020 REV. 003 17
CYLINDER REPLACEMENT:
The gas cylinders used to counterbalance the arm are wear items and will wear out over time. If the arm no
longer maintains counterbalance, (with proper counterbalance adjustment, see pg.8) it is a good indication
the gas cylinders need replaced.
The cylinder part number for your unit is screen printed in white on the black barrel of the cylinder. The
cylinder part number is prefixed by “C-16” and is followed by 5 numbers. When ordering replacement
cylinders, please provide the complete “C-16_ _ _ _ _” number from the cylinder on your unit.
Replacement cylinders installed by the customer carry a 30-day limited warranty from the date of purchase.
When replacing a gas cylinder, make sure not to scratch, mar, or nick the shaft on either the old cylinder being
replaced, or the new cylinder being installed. All warranty cylinders must be returned to FlexArm for
evaluation. The warranty is void if the cylinder to be evaluated shows signs of scratches or nicks on the
cylinder shaft or body.
Front Cylinder Replacement
1. Adjust the front cylinder by turning the hex on the top adjuster. Turning the
adjuster with a 3/16” Allen wrench (counter clockwise) until the dowel pin of the
adjuster reaches the lowest position in the slot of the top plates.
2. Hold the front arm securely. Once the screws in this step are removed, the front
arm will want to extend up! Remove the arm screws on the front plates (see
figure 11) so that the front arm is free and access to the front cylinder can be
made.
3. Once the screws are removed, slowly guide the front arm up to the fully extended
position (see Figure 12).
4. Remove the shoulder bolt attaching the cylinder to the front
arm. Note that there are two spacers on either side of the
cylinder clevis to hold the cylinder centered in the arm. Do not
lose these.
5. Unscrew the tube end of the cylinder, by hand, from the end
fitting attached to the adjuster.
6. Remove the end fitting from the tube end of the new cylinder.
Use care not to damage or scratch the cylinder rod. Dents or
scratches on the cylinder rod will cause the nitrogen gas to leak,
leading to the need for another cylinder.
Figure 11
Figure 12
10/29/2020 REV. 003 18
7. Using both hands; screw the tube end of the new cylinder into the end
fitting attached to the adjuster (see figure 13). It is only necessary to get
the cylinder hand tight – do not over tighten.
8. Replace the shoulder bolt attaching the cylinder to the front arm.
9. Reassemble the front arm to the front side plates with the front arm
screws removed in step 2.Use Loctite 242 when reassembling these
screws.
Rear Cylinder Change
1. Adjust the rear cylinder by turning (counter clockwise) the hex on the rear adjuster.
Turn the hex with a 3/16 all wrench until the pin of the adjuster reaches the lowest
position in the slot of the side plates.
2. Raise the two front arms to the fully extended position.
3. Hold the rear arm securely. Once the screws in this step are removed, the rear
arm will want to extend up! While supporting the front arms, remove the rear arm
screws on the rear side plates (see Figure 14) so that the rear arm is free and access
to the rear cylinder can be made. Carefully lower and place the front portion of the
FlexArm on the work surface after the rear arm screws have been removed. Care
must be exercised when taking the arm apart!
4. Remove the shoulder bolt attaching the rear cylinder to the rear arm. Note
that there are two spacers on either side of the cylinder clevis to hold the
cylinder centered in the arm. Do not lose these.
5. Unscrew the rod end of the cylinder, by hand, from the end fitting attached
to the adjuster (see Figure 15). You may need to wrap a towel or rubber
matting around the cylinder rod to remove it and to tighten the new
cylinder. Dents or scratches on the cylinder rod will cause the gas to leak
from the cylinder resulting in the need for another replacement cylinder and
voiding any warranty.
Figure 13
Figure 14
10/29/2020 REV. 003 19
6. Remove the end fitting from the rod end of the new cylinder. Use care
not to damage or scratch the cylinder rod. Dents or scratches on the
cylinder rod will cause the nitrogen gas to leak, leading to the need for
another cylinder.
7. Screw the new cylinder into the end fitting attached to the adjuster
(see Figure 16).
8. Replace the shoulder bolt attaching the cylinder to the arm. Remember
to place a spacer from step 4 on either side of the cylinder clevis.
9. Pull the rear arm down to the rear side plates. Reassemble the rear
arm to the rear side plates with the screws from step 3 (see Figure 17).
Use Loctite 242 when reassembling these screws.
Always re-adjust the arm’s counterbalance after replacing cylinders. (See pg. 8)
Figure 15
Figure 16
Figure 17
10/29/2020 REV. 003 20
PARTS & ASSEMBLY
ITEM QTY PART NUMBER DESCRIPTION
1 2 0369M 10-32 SHCS X 3/8" LG.
2 1 391 FILTER / LUBE ASSEMBLY
3 1 360024 1/2" NYLON TUBE - A32/S36
S-36-B S-36 ARM ONLY FOR TAPPER / DIE GRINDER
M-60-B M-60 ARM ONLY FOR TAPPER / DIE GRINDER
FX900110 400 RPM MOTOR, 9/16" CAPACITY
FX900115 400 RPM MOTOR WITH 3/8" JACOBS
FX900120 600 RPM MOTOR, 3/8" CAPACITY
FX900125 600 RPM MOTOR WITH 3/8" JACOBS
FX900130 1000 RPM MOTOR, 5/16" CAPACITY
FX900135 1000 RPM MOTOR WITH 3/8" JACOBS
FX900140 1500 RPM MOTOR, 1/4" CAPACITY
FX900145 1500 RPM MOTOR WITH 3/8" JACOBS
4
1
1
5
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