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FlexArm GH-24 Installation & Operation Manual

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GH-24, GH-30, GH-45, GH-60
INSTALLATION & OPERATIONS
MANUAL
FlexArm Inc.
Division of Midwest Specialties, Inc.
851 Industrial Drive
Wapakoneta, Ohio 45895
419-738-8147
800-837-2503 (toll free)
www.flexarminc.com
1 of 59
GH-24, GH-30, GH-45, GH-60
Rev.003

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Summary of Contents for FlexArm GH-24

  • Page 1 GH-24, GH-30, GH-45, GH-60 INSTALLATION & OPERATIONS MANUAL FlexArm Inc. Division of Midwest Specialties, Inc. 851 Industrial Drive Wapakoneta, Ohio 45895 419-738-8147 800-837-2503 (toll free) www.flexarminc.com 1 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 2 2 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...

  • Page 3: Table Of Contents

    Alignment Check List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...

  • Page 4: Safe Operation: Read This First

    If the Hydraulic Tapping Machine is going to be lifted with a crane, please call FlexArm for special instructions. o FlexArm is not responsible for accident or injury resulting from the misuse of this unit or for use other than originally designed and intended.

  • Page 5: Warranty

    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: o A FlexArm product that has had the serial number altered or removed.

  • Page 6: Technical Details

    Best Maximum Pressure (Bar) Security Maximum Pressure (Bar) Min Thread Capacity ¼” ¼” Max Thread Capacity 7/8” 1-1/4” 1-1/2” 2” 100-500 140-500 110-500 55-275 Oil Tank Capacity (Gallons) Max Torque (Ft/lbs) 78/63 188/63 325/63 811/162 6 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...

  • Page 7: Technical Details

    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 FlexArm Hydraulic Tapping Machines:...

  • Page 8: Installation

    When making repairs to this unit, always disconnect the main hooking up incorrect power supply could result in damage to the unit and void any existing warranty. Please Contact FlexArm with any questions or concerns about the installation of the FlexArm hydraulic tapping machine at 800-837-2503...
  • Page 9 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 FlexArm! (See Angle Mount Assembly Diagram Below)
  • Page 10 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.

  • Page 11: Installation

    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.
  • Page 12 1. Plug the unit in and turn on the red master switch on the rear of the unit. Ensure the emergency stop on front of the unit is pulled out and not engaged. 2. Pull out the front HMI display and wait for it to boot up. It should display as below: 12 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 13 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. 13 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...

  • Page 14: Start Up/Shut Down Procedure

    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. 14 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...

  • Page 15: Tap Lubricator System

    USE OF 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 is connected to the regulator-manometer which is adjusted in our factory.

  • Page 16: Multi Position Head

    4. When the head is used as shown in figure 2 and figure 3 you will need to break loose the hex head bolt on top. A wrench or socket will be needed for this. Figure 1 Figure 2 16 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 17 11. Remove the plug and re-insert the proper tap and begin tapping. NOTE: The multi-positional head allows taping in additional positions. This kind of tapping doesn't guarantee the perfect thread but will provide a good tapping quality. 17 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...

  • Page 18: Operating Instructions

    6. Actuate the hydraulic motor by depressing the forward button and gently guide the tap down to the hole (typically use lower gear; slow speed, for larger tap sizes). 18 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 19 BACKING OUT OF IT! THIS RESULTS IN POOR THREAD QUALITY, OVERSIZED THREADS. AND BROKEN TAPS! 9. To change tap holders, release the tap holder by pushing up on the collar of the quick change chuck. 19 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...

  • Page 20: Adjusting Tap Holder Torque Settings

    Rotate the snap ring and insert the tail in the secondary hole position.  To increase the torque setting, turn the thread ring clockwise.  To decrease the torque setting, turn the thread ring counter-clockwise. 20 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...

  • Page 21: Counterbalance Adjustment

    Moving the adjuster upward will decrease the retraction in the rear arm and decrease the extension on the front arm. Note: Extending the arms will make it easier to turn the adjuster handles. 21 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 22 PARTS BREAKDOWN: GH-24, GHM-24, GH-30 & GHM-30 22 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 23 PARTS BREAKDOWN: GH-24, GHM-24, GH-30 & GHM-30 23 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 24 PARTS BREAKDOWN: GH-24, GHM-24, GH-30 & GHM-30 24 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 25 PARTS BREAKDOWN: GH-24, GHM-24, GH-30 & GHM-30 25 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 26 PARTS BREAKDOWN: GH-45 & GHM-45 26 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 27 PARTS BREAKDOWN: GH-45 & GHM-45 27 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 28 PARTS BREAKDOWN: GH-45 & GHM-45 28 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 29 PARTS BREAKDOWN: GH-45 & GHM-45 29 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 30 PARTS BREAKDOWN: GH-60 & GHM-60 30 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 31 PARTS BREAKDOWN: GH-60 & GHM-60 31 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 32 PARTS BREAKDOWN: GH-60 & GHM-60 32 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 33 PARTS BREAKDOWN: GH-60 & GHM-60 33 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 34 PARTS BREAKDOWN: 2 SPEED GEARBOX 34 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 35 PARTS BREAKDOWN: 2 SPEED GEARBOX 35 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...

  • Page 36: Parts Breakdown

    PARTS BREAKDOWN: GHM-24 MULTI-HEAD 36 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 37 PARTS BREAKDOWN: GHM-30, 45, & 60 MULTI-HEAD 37 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 38 PARTS BREAKDOWN: SEMI TAP LUBRICATOR 38 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 39 PARTS BREAKDOWN: SEMI TAP LUBRICATOR 39 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 40 OPTIONAL ACCESORY: MECHANICAL DEPTH STOP 40 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 41 PARTS BREAKDOWN: GH POWER PACK 41 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 42 PARTS BREAKDOWN: GH POWER PACK 42 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 43 PARTS BREAKDOWN: GH POWER PACK 43 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 44 PARTS BREAKDOWN: GH POWER PACK 44 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 45 PARTS BREAKDOWN: ELECTRICAL CABINET 45 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 46 PARTS BREAKDOWN: ELECTRICAL CABINET 46 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...

  • Page 47: Removing The Chuck

    REMOVING THE CHUCK The chuck on the GH-24, GH-30 and the GH-45 is held on by a right hand, 8mm, socket head cap screw or hex head bolt. To remove the chuck you must remove this bolt with an Allen wrench. However, if you cannot hold the chuck and remove the bolt, you may have to make a tool to assist you.

  • Page 48: Cylinder Replacement

    CYLINDER REPLACEMENT DIAGRAM 48 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 49 REAR REPLACEMENT INSTRUCTIONS 1) With the FlexArm extended, turn the handle until the adjuster reaches the bottom most position in the slot. This removes all tension from the two cylinders. ( Having the arm extended makes it easier to turn the adjuster handle) 2) Change only one cylinder at a time (this prevents the unit from falling over).
  • Page 50 7) Screw the cylinder end of the new cylinder back into the upper adjuster. 8) Reattach the rod end of the new cylinder into the front arm using the pin and snap rings. 50 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 51 9) Take the LEFT front plate with the tool mount and reattach the two arm screws. 10) Take the RIGHT front plate and reattach the two arm screws and two tool mount screws. Tighten the set screw in the Right front plate. 51 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...

  • Page 52: Hydraulic Gearbox Disassembly

    NOTE: DO NOT LOOSE THE BALL AND SPRING (Item 21 and 22). 10) Reassemble in the reverse order. Make sure to grease all components. 52 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...

  • Page 53: Maintenance

    MAINTENANCE  Lubricate the base mount o The base mount of the FlexArm requires periodic care and maintenance. Monthly lubrication or bi- monthly lubrication is adequate. If it is necessary to remove the unit from the base mount, do not allow the lower bore of the angle mount or the base mount shaft to be contaminated by dirt or foreign materials.

  • Page 54: Maintenance

    The exposed exterior surface on the shaft of the FlexArm’s rear pin must not come in contact with any foreign material. If the FlexArm is not going to be immediately repositioned in the angle mount, wrap the rear pin with a clean, dry cloth, paper towel or plastic sheet.

  • Page 55: Troubleshooting

    TROUBLESHOOTING Refer to the following list of common problems when it appears the FlexArm is not working properly. Most of these are resolvable by in-house technicians or operators. Compare any problems with those given in the examples below. Help is just a phone call away; always contact Factory Service at 800-837-2503 with any questions or concerns about the FlexArm Tapping Machine.
  • Page 56 Any of these factors can cause the unit to tap a hole that isn’t straight or even prevent the unit from tapping the hole. o Verify the tap capacity of the unit purchased has not been exceeded. 56 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...
  • Page 57 NOTE: The unit has a Limited Warranty on parts and labor. This warranty is void if changes to the unit or attempts to repair it or its components are made without the express authorization of FlexArm Inc. Quick change tap holders are considered perishable items and are not covered by the limited, three year warranty on the FlexArm Tapping Machine.
  • Page 58 (LS/012) when the lever is actuated, the fluid flow control valve is defective.  When the lever is actuated fluid comes out but no air o Follow same instructions as if nothing comes out. 58 of 59 GH-24, GH-30, GH-45, GH-60 Rev.003...

  • Page 59: Alignment Check List

     How is the part being fixture? The fixture must be parallel to the FlexArm. Are the fixtures moved?  Is the part fixture level to the FlexArm Base Mount? The work piece must be secure and level to the FlexArm base.

This manual is also suitable for:

Gh-30Gh-60Gh-45

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