FlexArm A-32 User manual

INSTALLATION & OPERATIONS MANUAL
FLEXARM A-32
FlexArm Inc.
Division of Midwest Specialties, Inc.
705 Commerce Drive
Wapakoneta, Ohio 45895
419-738-8147
800-837-2503 (toll free)
www.flexmachinetools.com

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TABLE OF CONTENTS:
Safe Operation: READ THIS FIRST - - - - - - - - - - - - - - - - - - - -
3
Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
4
Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
5-6
Counterbalance Adjustments - - - - - - - - - - - - - - - - - - - - - - -
7
Operating Instructions - - - - - - - - - - - - - - - - - - - - - - - - - - - -
8-9
Adjusting Torque Holder Clutch Setting - - - - - - - - - - - - - - -
10
Torque Requirements for Tapping Chart - - - - - - - - - - - - - - -
11
Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
12-13
Drawing: A-32 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
14
Cylinder Replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - -
15-17
Parts and Assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
18-23
Troubleshooting - - - - - - - - -- - - - - - - - - - - - - - - - - - - - - - - -
24-26

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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.

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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.

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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.
Figure 1
Figure 2

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4. Install the unit’s airline into the press-to-release airline fitting (see Figure 2).
5. Cut and remove the shipping zip tie strap (see Figure 2).
6. Install a ¼” NPT fitting into the incoming air port on the unit’s filter / lubricator (see Figure 2). 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.
7. 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.
8. With the motor running, slowly adjust the lubricator adjustment
knob (see Figure 3) 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.
9. The filter is equipped with an auto drain and will automatically remove water from the filter bowl.
10. 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.
11. To adjust the counterbalance, refer to the counterbalance adjustment page of this manual.
12. The unit is now ready for use.
Figure 3

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COUNTERBALANCE ADJUSTMENT
To adjust the counterbalance, loosen the knob on the weight block and slide the block up or down the arm.
Tighten the knob to set the position of the block. Moving the block towards the motor will decrease the
counterbalance and moving the block away from the motor will increase the counterbalance. See Figure 4.
**When the arm is not in use, slide the weight block towards the rear of the arm to keep the motor in an
upward position. This will extend the life of the cylinder.**
Figure 4

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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 5).
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 6).
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 5
Figure 6

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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.

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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 7 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 8.
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 7
Figure 8

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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

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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 13
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.

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DRAWING: A-32

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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.7) 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.
Read each step completely before starting.
1. Remove the air supply from the arm and the hose from the quick-release fitting on the motor.
**For steps 2-5, see Figure 9**
2. Remove the motor mount screws (2)
using a 5/16” Allen wrench and slide
the motor out of the mount.
3. Remove the cable tie connecting the
arm boot to the front block. Slide the
boot off the front of the arm.
4. Remove the 6 bolts holding the plate
on the bottom of the arm guard.
5. Remove the 4 bolts holding the arm
guard. Slide the arm guard with the
weight block and end cap toward the
back of the FlexArm and remove. This
will expose the inside of the arm.
Figure 9

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6. Remove the upper arm screw as shown
in Figure 10. Only remove 1 screw (does
not matter which side). Using an Allen
wrench or pin punch, push the arm pin
completely out, leaving the wrench or
punch in place.
CAUTION: Make sure not to damage the
arm pin threads. Also, the cylinder may
still have some pressure. The unit will
shift once the pin is out and the wrench
or punch will be held tightly in the
location where the arm pin used to be.
7. Squeeze the upper and lower arms
together with both hands. This will take any pressure off the wrench or punch and allow you to remove it.
CAUTION: Slowly let the arms spread apart. The upper arms will raise to their highest point. The bottom
arms should be guided gently downward to the work surface (see Figure 11).
NOTE: The arm pin washers will fall out during this operation. Make sure not to lose them. Reassembly
without these washers will result in the arm binding during operation. There must be one washer for each
end of the arm pin.
8. Remove the 10-32 flat head screws (2) holding the cylinder pin in the lower arm. Rotate the upper arms
upward so the cylinder can hang freely. Grab the body of the cylinder and rotate it (by hand)
counterclockwise to remove it from the clevis. See Figure 11.
9. On the new cylinder, remove the clevis on the body end and tighten it by hand to the existing clevis on the
arm. The cylinder only needs to be snug; do not overtighten.
10. Install the cylinder pin and nylon spacers onto the new cylinder. With the upper arms in the highest
position, reinstall the new cylinder to the bottom arms by aligning the cylinder pin with the holes in the
bottom arm. Fasten the 10-32 flat head screws to secure the cylinder to the bottom arms. See Figure 11.
NOTE: The new
cylinder should be
installed in the
same orientation
as the original
cylinder. The rod
end of the cylinder
should be
connected to the
bottom arms and
the body end of
the cylinder
should be
connected to the
top arms.
Figure 11
Figure 10

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11. Raise the bottom two arms in
the horizontal position and
place onto a riser. The riser
should be approximately 14” tall
and be capable of withstanding
150 lbs. of force. The angle
mount should be positioned in a
straight line with the arms. See
Figure 12.
12. Place a small amount of grease
or oil onto one of the arm pin
washers and position the
washer over the arm pin hole on
the inside of the upper arm. This
will keep the washer from
falling.
13. With the motor mount and lower arms supported on the riser, compress the upper arms downward until
the arm pin can be pushed into the hole and through the washer that was just installed.
14. Once the arm pin and washer are started, it is necessary to install the remaining washer on the other side.
Tap the arm pin until there is enough clearance to lower the second washer between the upper arm and
front block.
NOTE: If the bearing unseats itself from the front block, it may be necessary to gently push it back into
place by sliding a flat screwdriver between the upper arm and front block.
15. Once the second washer is in place, tap the arm pin through. Place Loctite 242 or 243 on the arm screw
threads and install the arm screws.
NOTE: Do not overtighten the arm screws. The screws should be snug only. Overtightening could affect the
smooth movement of the arm.
16. Slide the arm guard cover over the arms and start all 4 bolts before tightening. Attach the bottom arm
guard plate and start all 6 bolts before tightening.
17. Slide the boot back onto the arm. Place a new cable tie on the arm boot where it connects to the front
block.
18. Install the motor back into the motor mount and secure it with the two socket head screws. Reattach the
tube to the quick connect fitting on the motor.
NOTE: The slots on the motor body need to line up with the two socket head bolts.
Always re-adjust the arm’s counterbalance after replacing cylinders. (See pg. 7)
Figure 12

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PARTS & ASSEMBLY
ITEM QTY PART NUMBER DESCRIPTION
1 1 A32 TAPPING ARM A32 TAPPING ARM (NO MOTOR)
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
1
2

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ITEM QTY PART NUMBER DESCRIPTION
1 2 0369M 10-32 SHCS X 3/8" LG.
2 2 0376M 3/8-16 SHCS X 1 1/2" LG.
3 1 0391 FILTER / LUBE ASSEMBLY
4 1 0604M RUBBER BOOT
5 2 0609M THRUST WASHER FOR A32 ANGLE
6 4 0611M ANGLE THRUST WASHER
7 1 0612M 7/8-14 LOCKNUT
8 3 0613M 1/4-20 SHCS X 1 3/4" LG.
9 4 0621M 10-32 BHSS X 1/2" LG.
10 60627M 6-32 X 1/4" ROUND HD. SCREW
11 11110 A-32 MOTOR MOUNT
12 11165 PARALLEL ARMS ASSEMBLY
13 11185 ANGLE WITH BEARINGS
14 11195 BASE WITH BEARINGS
15 11225 ARM GUARD ASSEMBLY
16 11240 A-32 ARM GUARD PLATE
17 1360024 1/2" NYLON TUBE - A32/S36

10/29/2020 REV. 003 20
ITEM QTY PART NUMBER DESCRIPTION
1 1 0385M ELBOW FITTING, 1/2" O.D.
2 1 0391M FILTER / LUBRICATOR NO ELBOW
ITEM QTY PART NUMBER DESCRIPTION
1 1 420002 FILTER / LUBE MOUNT BRACKET
2 1 420006 LUBRICATOR HALF