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Related Manuals for FlexArm GH-24
Summary of Contents for FlexArm GH-24
- Page 1 INSTALLATION & OPERATIONS MANUAL HYDRAULIC TAPPING ARMS GH-24, GH-30, GH-45, GH-60 GHM-24, GHM-30, GHM-45, GHM-60 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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Page 2: Table Of Contents
TABLE OF CONTENTS: Safe Operation: READ THIS FIRST - - - - - - - - - - - - - - - - - - - - Warranty - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Specifications - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Electrical Installation - - - -- - - - - - - - - - - - - - - - - - - - - - - - - - Arm Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -... -
Page 3: Safe Operation: Read This First
• 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. -
Page 4: Warranty
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: •... -
Page 5: Specifications
SPECIFICATIONS TECHNICAL DETAILS CHART MODEL GH-24 GH-30 GH-45 GH-60 Electric Motor (HP) Operating Pressure (Bar) Min Thread Capacity 1/4" 1/4" 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 (lbf-ft) 78/63 188/63... - Page 6 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: Hydraulic Oils...
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Page 7: Electrical Installation
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. -
Page 8: Arm Installation
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 FlexArm ! (See... - Page 9 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 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.
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Page 11: Start Up Procedure
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. - Page 12 Start Stop Validation Speed Enter 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.
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Page 13: Shut Down Procedure
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. -
Page 14: Tap Lubricator System
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. -
Page 15: Operator Instructions
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 Figure 1 ring. -
Page 16: Adjusting Torque Holder Clutch Setting
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. -
Page 17: Torque Requirements For Tapping
TORQUE REQUIREMENTS FOR TAPPING: Aluminum and 200 BHN 300 BHN 400 BHN Approx. Torque Holder Brass Tap Size leaded brass Steel Steel Steel Break Torque Factory Setting (in/lbs) (in/lbs) (in/lbs) (in/lbs) (in/lbs) (in/lbs) (in/lbs) 2.25 4.25 5/16 18.5 7/16 94.5 9/16 59.5 1,000... -
Page 18: Multi-Position Head Operating Instructions
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. - Page 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.
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Page 20: Counterbalance Adjustment
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. -
Page 21: Parts Breakdown: Arms
PARTS BREAKDOWN: GH-24, GHM-24, GH-30 1/26/2021 REV. 007... - Page 22 PARTS BREAKDOWN: GH-24, GHM-24, GH-30 Item Part Number Description Qty. G30-0021 TOP ADJUSTER (STRAIGHT) G30-0022 TOP PLATE (SPECIFY RIGHT OR LEFT HAND) G30-0027 CYLINDER SCREW S_ _ _ _ _ _N FRONT CYLINDER, SHORT (SPECIFY NEWTONS) G30-0023 ARM, FRONT (GH-30)
- Page 23 PARTS BREAKDOWN: GH-24, GHM-24, GH-30 Detail A Item Part Number Description Qty. G30-0013 BUMPER FOR REAR PIN G30-0035 REAR PIN G30-0001 SCREW FOR REAR PIN, FLATHEAD G30-0055 BEARING FOR ANGLE G30-0056 BEARING SPACER FOR ANGLE G30-0033 ANGLE MOUNT (NO BEARINGS OR SPACER)
- Page 24 PARTS BREAKDOWN: GHM-30, GH-45, GHM-45 1/26/2021 REV. 007...
- Page 25 PARTS BREAKDOWN: GHM-30, GH-45, GHM-45 Item No Part No Description QTY Used G45-0501 Top Adjuster G45-0502 Top Plate (Specify right or left hand) G45-0123B Upper Cylinder Clevis L_ _ _ _ _ _N Front Cylinder (Long Style) Specify Newtons G45-0503 Arm, Front (GH-45) (No Bearings/Pins See Detail B) G45-0503M Arm, Front (GHM-45) (No Bearings/Pins See Detail B)
- Page 26 PARTS BREAKDOWN: GHM-30, GH-45, GHM-45 For Detail A Item No Part No Description QTY Used G45-0520C Bumper for Rear Pin G45-0128 Rear Pin G45-0127 Screw for Rear Pin, Flathead G45-0526 Bearing for Angle G45-0527 Bearing for Spacer for Angle G45-0514 Angle Mount (No Bearings or Spacer) G45-0526 Bearing for Angle...
- Page 27 PARTS BREAKDOWN: GH-60 & GHM-60 1/26/2021 REV. 007...
- Page 28 Item No Part No Description QTY Used G60-0499 Top Adjuster G60-0682 Top Plate (Specify right or left hand) G45-0123B Upper Cylinder Clevis L-1500N Front Cylinder G60-0683 Arm, Front (GH-60) (No Bearings/Pins See Detail B) G60-0683B Arm, Front (GHM-60) (No Bearings/Pins See Detail B) G60-0123A Lower Cylinder Clevis (Square) G60-0124...
- Page 29 PARTS BREAKDOWN: GH-60 & GHM-60 For Detail A Item No Part No Description QTY Used G60-0520E Bumper for Rear Pin G60-0691 Rear Pin G60-MS003 Screw for Rear Pin, Flathead G60-0413 Washer Top of Angle at Rear Pin G60-0071 Bearing & Cup G60-0072 Bearing &...
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Page 30: Parts Breakdown: 2-Speed Gearbox
PARTS BREAKDOWN: 2 SPEED GEARBOX 1/26/2021 REV. 007... - Page 31 PARTS BREAKDOWN: 2 SPEED GEARBOX GH/GHM-30 GH/GHM-45 GH/GHM-60 GH/GHM-60 Item Part Number Part Number Part Number Part Number Description Qty. 0.596 1.296 DIMENSION A SINGLE SINGLE SINGLE DUAL # OF KEYS ON SPINDLE 2GB-001 3GB-001 4GB-001 4GB-001 GEAR BOX FLANGE 2GB-002 3GB-002 4GB-002...
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Page 32: Parts Breakdown: Accesories
PARTS BREAKDOWN: GHM-24 MULTI-HEAD Item Part Number Description Qty. G30-0031 WASHER WITHOUT COUNTER SINK G30-0034 WASHER WITH COUNTER SINK G30-MS005 SCREW FLAT HEAD G30-0700 LATERAL PIN G30-0701 REAR ALUMINUM BLOCK G30-0634 LEVER (LARGE) FOR MULTI-HEAD G30-0633 LEVER (SMALL) FOR MULTI-HEAD G30-0702 THREADED BRAKE (BRASS) G30-0703... - Page 33 PARTS BREAKDOWN: GHM-30, 45, & 60 MULTI-HEAD Item GHM 45 Part # GHM 60 Part # Description G45-0127 G45-0127 FLAT HEAD SCREW G45-0703 G45-0515 WASHER WITH COUNTER SINK G45-0706 G60-0403 LATERAL FEMALE BRAKE G45-0707 G45-0707 FLAT HEAD SOCKET SCREW G45-0708 G45-0708 FLAT HEAD SOCKET SCREW G45-0709...
- Page 34 PARTS BREAKDOWN: SEMI TAP LUBRICATOR 1/26/2021 REV. 007...
- Page 35 PARTS BREAKDOWN: SEMI TAP LUBRICATOR Item Part Number Description Qty. RNR038 FILL PLUG LS010 AIR FLOW CONTROL VALVE 0504M 0515M MANIFOLD BLOCK LS012 NOZZLE (DOES NOT INCLUDE INTERNAL FLUID HOSE) LS014 MANIFOLD WITH NOZZLE & INTERNAL FLUID HOSE LS013 ELBOW FITTING LS001 LEVER SLEEVE LS015...
- Page 36 OPTIONAL ACCESORY: MECHANICAL DEPTH STOP 1/26/2021 REV. 007...
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Page 37: Parts Breakdown: Power Pack
PARTS BREAKDOWN: GH POWER PACK 1/26/2021 REV. 007... - Page 38 PARTS BREAKDOWN: GH POWER PACK 1/26/2021 REV. 007...
- Page 39 PARTS BREAKDOWN: GH POWER PACK 1/26/2021 REV. 007...
- Page 40 PARTS BREAKDOWN: GH POWER PACK 1/26/2021 REV. 007...
- Page 41 PARTS BREAKDOWN: ELECTRICAL CABINET 1/26/2021 REV. 007...
- Page 42 PARTS BREAKDOWN: ELECTRICAL CABINET 1/26/2021 REV. 007...
- Page 43 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.
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Page 44: Cylinder Replacement
CYLINDER REPLACEMENT DIAGRAM 1/26/2021 REV. 007... - Page 45 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 46 FRONT REPLACEMENT INSTRUCTIONS MODELS GH-36, GH-45, GHM-45 1) With the front arm partially extended, turn the handle until the adjuster reaches the bottom-most position. (having the arm extended partially makes it easier to turn the adjuster handle) 2) Remove the top two bolts on the front plate that keep the front arm attached a.
- Page 47 FRONT REPLACEMENT INSTRUCTIONS MODEL GH-60 1) With the front arm extended in the horizontal position, turn the handle until the top adjuster reaches the bottom-most position. (having the arm extended makes it easier to turn the adjuster handle) 2) With the arms folded up and strapped, loosen the set screw on the RIGHT front side plate. Remove the two arm screws and two tool mount screws from the same RIGHT plate.
- Page 48 HYDRAULIC GEARBOX DISASSEMBLY NOTE: (SEE DIAGRAM on page 30) 1) Remove the (4) metric socket head cap screws which hold the gearbox cover and motor to the gearbox. 2) Remove the motor and cover together. 3) Loosen the set screw and remove Item 16 (dial switch) 4) Remove the two screws, Item 17.
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Page 49: Maintenance
MAINTENANCE ● Lubricate the base mount o The base mount of the FlexArm requires regular 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 50 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.
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Page 51: 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 52 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, one-year warranty on the FlexArm Tapping Machine.
- Page 53 TROUBLESHOOTING SEMI TAP LUBRICATOR NOTE: Reference diagram on pg. 34 & 35 The lever is actuated, but nothing comes out ● o You must first determine if the problem is air or fluid. Follow the airline from the pneumatic motor to the air microvalve (LS/006) located between the plates.
- Page 54 ● How is the part being fixtured? The fixture must be parallel to the FlexArm. Are the fixtures moved? ● Is the part fixture level to the FlexArm Base Mount? The workpiece must be secure and level to the FlexArm base.