LRP® - Linear Rod Pump – M echanical M anual Linear Rod Pump Systems MECHANICAL INSTALLATION AND MAINTENANCE MANUAL M anual # 2.0.2 Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 1 of 32 LRP ® - Linear Rod Pump – M echanical M anual TECHNIC AL S PECS :.......................................................................................................................3 S AFETY INFORMATION ...............................................................................................................5 OVERVIEW.........................................................................................................................................5 CONVENTIONS USED.........................................................................................................................6 GENERAL PRECAUTIONS ...................................................................................................................6 INSTALLATION PRECAUTIONS ...........................................................................................................7 MAINTENANCE PRECAUTIONS ..........................................................................................................8 SAFE SERVICE PRACTICES ................................................................................................................9 2 INS TALLATION ..........................................................................................................................12 2.1 O VERVIEW................................................................................................................................12 2.2 INSTALLATION GUIDELINES ....................................................................................................12 2.2.1 Long Term Storage...........................................................................................................12 2.2.2 Site Planning....................................................................................................................12 2.2.2.1 S tand..........................................................................................................................12 2.3 INSTALLATION..........................................................................................................................13 2.3.1 Electrical Connections .....................................................................................................13 2.3.2 Unit Height:......................................................................................................................13 2.3.3 Lifting:..............................................................................................................................14 2.3.4 Brake information:...........................................................................................................15 2.3.5 Proximity switch installation:..........................................................................................16 2.3.6 Installing the LRP® unit on the Well Head....................................................................17 2.3.6.1 Installing with polished rod in LRP® unit.............................................................17 2.3.6.2 Install over the polished rod. ...................................................................................18 2.3.7 Fill the unit with oil..........................................................................................................19 2.3.7.1 Base fill port..............................................................................................................19 2.3.7.2 Gearbox:....................................................................................................................20 2.3.8 Optional rod rotator: ........................................................................................................22 2.3.9 Top cover installation:......................................................................................................23 2.3.10 Post Installation Checks: ...............................................................................................24 3 MAINTEN ANCE: .........................................................................................................................25 3.1 OIL CHANGE:...........................................................................................................................25 3.1.1 Gearbox oil:......................................................................................................................25 3.1.2 Rack and Pinion oil..........................................................................................................25 3.1.2 Draining oil from the LRP® unit. ...................................................................................27 3.3 BOLT TORQUE:........................................................................................................................31 3.4 SEALING MATING SURFACES OIL TIGHT:.................................................................................31 3.5 PREVENTATIVE MAINTENANCE SCHEDULE:...........................................................................32 3.6 S PARE / REPLACEMENT PARTS :...............................................................................................32 Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 2 of 32 LRP ® - Linear Rod Pump – M echanical M anual Technical Specs: (Veri fy this info with the tag on the machine) M odel #: ___________________________________ Serial #: ____________________________________ Gear ratio: __________________________________ Tag location at the base of the LRP. Actual brake engagement RPM :_________________ Lifting capacity: 30,000 lbs Linear Lead (one turn of the pinion): 18.8495 in/rev M ax torque setting (gearbox output torque): 90,000 in-lbs Brake: Bolt torque: 75 ft-lbs (8 places) Type of oil: M obilgear 600xp 220 (or equivalent) 86 Rated Stroke: (inches) 91 Actual Stroke: (inches) Rack and guide weight: (lbs) 1260 LRP weight without oil: (lbs) 5250 130 Unit Height: (inches) Over all height above stand: (inches) 270.75 Overall height above stand with rod rotator: (inches) 275.5 Gearbox oil capacity: (gal ) 10.3 20 Base oil capacity: (gal) 100 105 1395 5750 144.5 299.5 304.25 10.3 22.5 120 125 1588 6250 1588 339.5 344.25 10.3 26.1 M odel number example: L=LRP STROKE: RATIO: MOTOR FRAME: TORQUE VALUE: REVISION NUMBER: OPTIONS: RR=ROD ROTATOR Customer information: Well location : ______________________________________________________ Well No.: _________________________________________________________ Install Date: _______________________________________________________ Notes: __________________________________________________________ _______________________________________________________________ _______________________________________________________________ Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 3 of 32 Linear Rod Pump – M echanical M anual Rod rotator option: Top cover Guide roller Brake Gearbox Pinion Pinion housing M otor Rack Base Stand Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 4 of 32 .LRP ® . drive. When your LRP® unit is delivered. It is the responsibility of the owner/operator of this equipment to ensure that it is properly maintained and safety inspected at regular scheduled intervals. Keep non-qualified personnel at a safe distance from this equipment. If there is any question of the safety of a procedure. Installation and repair procedures require specialized skills with mechanical pumping systems. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 5 of 32 . This equipment contains high voltages. It is the responsibility of the owner/operator of this equipment to ensure that it is correctly and safely installed.LRP ® . Any person that installs or repairs this unit must have these specialized skills to ensure that it is safe to operate. It is the responsibility of the owner/operator of this equipment to ensure that it. Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt startup or troubleshoot this equipment. operating. Contact the Unico. Only qualified personnel should attempt startup or troubleshooting of this equipment. 5. It is the responsibility of the owner/operator of this equipment to ensure that any person operating it has access to all manuals and information required for its safe use and operation. as failure to follow these instructions may lead to personal injury or death. Inc before starting. It is the responsibility of the owner/operator of this equipment to ensure that any person operating it has been properly trained. 4. Improper use can cause serious or fatal injury. motor. and/or driven equipment. It is the responsibility of the owner/operator of this equipment to ensure that any person who has not been trained on the safe use of this equipment does not have access to it. Only qualified personnel familiar with the safe installation. when installed fully. • • • • • System documentation must be available to anyone that operates this equipment at all times. 3. it becomes the responsibility of the owner/operator of the unit to provide safe conditions and operation of the equipment. and troubleshooting this equipment. Study this information carefully before working with this equipment. Some responsibilities include (but are not limited to) the following: 1. 2. Inc. operation and maintenance of this device should attempt startup or operating procedures. Always ensure any connected equipment capable of falling is safely secured by approved methods prior to working on this unit. Therefore if you use a procedure that is not recommended in this manual. The precaution statements are general guidelines for the safe use and operation of this LRP® system. service department for repairs or any questions you may have about the safe installation and operation of this system. It is not possible to list all unsafe conditions. Always disconnect power before making or removing any connections. please contact Unico.Linear Rod Pump – M echanical M anual Safety Information Overview This section states important safety information that must be followed when setting up. or damage to the unit. This equipment has moving parts. you must determine if it is safe for the operator and all personnel in the proximity to the unit. complies with all federal. 6. state and local codes. Be sure to keep a copy of this manual with the unit so that all users can be properly informed of its safe operation. Some parts of this unit move during operation. Never touch a part of the equipment until all moving parts are completely stopped.LRP ® . This equipment may be connected to other moving parts. Never allow children or pets to be in the area where the equipment is running. Never start the equipment unless you have first verified that the installation and operation are as described in this manual. Become familiar with the controls and safety systems provided with this equipment. Be sure that you are completely familiar with the safe operation of this equipment. Be sure that you understand how to stop the unit quickly in case of an emergency situation. all electrical power must be removed to prevent accidental movement during servicing. The unit may cause injury or death. Also. Never permit anyone to operate the equipment without proper instructions. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 6 of 32 . Rotating parts can present extreme danger if clothing or body extremities are caught by the rotating part and can cause serious or fatal injury. Improper operation may cause violent motion of connected equipment. General Precautions Never operate this unit in a manner other than as described in this manual. property damage. Improper use can cause serious or fatal injury. or economic loss.Linear Rod Pump – M echanical M anual Conventions Used The following notation convention is used throughout this manual to indicate information important to personal safety or machine hazards. Identifies information about practices or circumstances that can lead to personal injury or death. Operation in any manner not described in this manual should be considered unsafe and should not be attempted. Be certain that unexpected movement will not cause injury to personnel or damage to equipment. Do not put hands. etc. Never operate machinery when physically or mentally fatigued. When operating this equipment remain alert at all times. Electrical shock can cause serious or fatal injury. Any person that installs or performs repairs must have these specialized skills to ensure that the unit is safe to operate. Never operate electrical equipment while standing in water. NEC requires that the frame and exposed conductive surfaces (metal parts) be connected to an approved earth ground. gearing. Contact Unico. covers. Installation Precautions Installation and repair procedures requires specialized skills with electrical equipment and mechanical pumping systems. feet. tools clothing or other objects near moving parts. shields and other safety items are properly installed. Place protective covers over all moving parts such as motor shaft and fan. drugs or medication. Local codes may also require proper grounding of equipment systems. M oving parts cause extremely dangerous situations because they can catch loose clothing or extremities and cause serious or fatal injury. M oving parts cause extremely dangerous situations because they can catch loose clothing or extremities and cause serious or fatal injury. Electrical shock can cause serious or fatal injury. for installation or repairs. feet or shoes or while barefoot.Linear Rod Pump – M echanical M anual Never operate the equipment unless all guards. on wet ground or with wet hands. Be sure all wiring complies with the National Electrical Code (NEC) and all regional and local codes or CE Compliance. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 7 of 32 . High voltage is present whenever the equipment is running.LRP ® . Do not apply AC power before you ensure that grounds are connected. Inc. Improper wiring may cause a hazardous condition and exposure to electrical hazards can cause serious injury or death. Be sure the system is properly grounded before applying power. or while under the influence of alcohol. Be careful where you place fingers and toes to prevent injury. use reasonable caution. Inc. Electrical shock can cause serious or fatal injury. Always treat electrical circuits as if they are energized. Never start a unit that has been modified or tampered with. Before cleaning. Using the correct parts will assure continued safe operation as designed. After stopping.LRP ® . Never try to lift equipment without an appropriate hoist or lifting means. always be sure the unit has stopped and that all moving parts have also stopped. inspecting. Electrical shock can cause serious or fatal injury. repairing or performing any maintenance to the equipment. broken or frayed wiring or wires with damaged insulation immediately. certain components may retain significant potential energy due to gravity. Disconnect all electrical wires and load devices from equipment power outlets before servicing the equipment.Linear Rod Pump – M echanical M anual Unauthorized modification of equipment may make the unit unsafe for operation or may impair the operation of the unit. Be sure that all covers and guards are properly installed and that the unit is safe before starting. Electrical shock can cause serious or fatal injury. If you are unsure. Circuit overload protection must be provided in accordance with the National Electrical Code and local regulations. Always treat electrical circuits as if they are energized. Electrical shock can cause serious or fatal injury. Have electrical circuits and wiring installed and checked by licensed electrician or qualified technician. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 8 of 32 . contact Unico. Ensure all loads are properly secured to prevent accidental motion. Use only original equipment or authorized replacement parts. as it is heavy and bodily injury may result. Maintenance Precautions Disconnect all electrical power before servicing the equipment. Inspect all wiring frequently and replace any damaged. When moving the equipment. The restart function must not be enabled when hazardous conditions might arise from such action. Equipment Control Precautions An incorrectly installed or operated drive can result in damage to the equipment it controls. The LRP® unit may start automatically whenever power is applied or after a fault trip if the auto restart has been enabled. These points are not designed for the weight or lifting angle needed for the LRP® unit. Regardless of the operating state. Safe Service Practices Follow industry-recognized safety procedures: • Use only one hand to hold test equipment probes • Wear approved eye protection • Stand on insulated material • Use an isolated oscilloscope • Keep unnecessary personnel out of the work area • Never leave a drive cabinet open or unattended • Never work alone Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 9 of 32 . Control inputs do not generate an emergency stop of the motor and do not remove electrical power that can cause hazardous conditions. M ake certain installation and operating specifications are followed. the drive’s motor output terminals may be at dangerous voltage levels whenever input power is applied and the bus is charged.Linear Rod Pump – M echanical M anual Do not lift the equipment from the motor or gearbox lifting points.LRP ® . 1 Overview This chapter describes the contents and intended audience of this document. • Chapter 1. Installation. About this Manual. 1.2. 1. describes the maintenance of the Unico LRP® system. Overview of this document.LRP ® 1 . discusses safety hazards and precautions important to anyone working with this equipment.1 What’s Covered • Safety Information. and spare parts • Detail listing of basic drive parameters • Drive setup and auto tuning procedures • Interface setup and diagnostic utilities Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 10 of 32 . maintenance. 1. • Chapter 2. describes the installation of the Unico LRP® system.2 What’s Not Covered This manual does not address basic hardware and firmware aspects of the drive. Please refer to those documents for: • Unpacking and receiving instructions • Hardware features and specifications • Electrical installation instructions • Drive troubleshooting. • Chapter 3.2.Linear Rod Pump – M echanical M anual About this Manual 1. These topics are covered in the drive installation and firmware instruction manuals. Maintenance.2 Contents The manual provides the instructions and technical information necessary to complete the mechanical installation of the LRP® unit. operating. Start-up and operation should be performed by personnel familiar with both the drive and the machinery or equipment interfaced.3 Intended Audience This manual is intended for anyone who will be installing. and electrical schematics. Please familiarize yourself with these regulations. Read all manuals first Read this manual as well as the Linear Rod Pump Operating Instruction manual and the drive software application and installation and firmware instruction manuals entirely before installing the drive. This unit must be operated in the manner prescribed by this document. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 11 of 32 . No prior experience with the drive is presumed or required. Consult with the factory if unsure on any topic before proceeding. electrical wiring practices and components.Linear Rod Pump – M echanical M anual 1.LRP ® . Follow instructions You can prevent injury and damage to the drive or equipment by carefully following the procedures outlined in this manual. and servicing the LRP® system. Installation should be performed by qualified personnel to ensure that correct practices and applicable codes are applied. The audience is expected to have a basic knowledge of physical and electrical fundamentals. Follow regulations All electrical work should conform to the National Electrical Code as well as all state and local government regulations. Uses outside those prescribed shall invalidate the manufacturer’s warranty.4 Intended Application Unico LRP® systems are intended for vertical rod pump applications. 1. 2. M A 02169-7471 USA 2. For trouble free service. The following sections provide guidelines for successful installations.1 S tand • The unit is intended for mounting on a separate mounting stand that is supported by a casing or tubing flange. • Ensure the base is concentric and perpendicular to the polished rod. read and follow the gearbox manufacturer’s operating instructions provided with the LRP®’s manual. notify UNICO of the shortage or damage. Note the damage or shortage on the freight bill of lading and file a claim with the carrier. In addition to these instructions. 1 Batterymarch Park. 30 – Storage.2.2 Installation Guidelines The procedures presented in this manual are suggestions and it is the responsibility of the Owner/Operator to arrange for these procedures to be performed by licensed contractors according to all applicable codes including local codes for your M unicipality/City/County and State/Province. 2. protected area. Appropriate shims or adjustments to the base and mounting stand may be necessary. Before shipment. checked and properly packed. • It is the user’s responsibility to ensure there is adequate integrity of the well completion for the gas and fluid flow when the base is installed. it should be stored in a dry. these instructions contain important recommendations on maintenance. Additionally.2. NFPA (National Fire Protection Association) (617) 770-3000 (includes NEC). Quincy.Linear Rod Pump – M echanical M anual Installation 2.2. please inspect the unit immediately upon arrival for shortage or transit damage.2 Site Planning This equipment system is enclosed and is designed for outdoor use.2. Handling and Use of Flammable Liquids.LRP ® 2 .1 Long Term S torage If the unit is not installed immediately. Also. Units which are used for standby service should be stored sealed. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 12 of 32 . However. every LRP® unit is tested. See your local building inspector. proper installation and operation are essential. 2.1 Overview These operating instructions are intended to help you install and operate the LRP® unit. Local Codes applicable to mechanical equipment installation. • • National Fire Protection Association o No. 3.2 Unit Height: Unit height is from the top of the stand to the rod clamp surface. This dimension can be found in the technical specs of this manual. 2. The procedures presented in this manual are suggestions and it is the responsibility of the Owner/Operator to arrange for these procedures to be performed by licensed contractors according to all applicable codes including local codes for your M unicipality/City/County and State/Province. There is 45” between the rod clamp surface and the inside of the top cover. The polished rod should not be more than 45” above this dimension. Note: Use this to determine the height of the polished rod.3 Installation The equipment is completely assembled. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 13 of 32 . tested and adjusted at the factory before it is shipped.3. External connections required at the time of installation are: 2.Linear Rod Pump – M echanical M anual 2.LRP ® .1 Electrical Connections Consult supplied electrical drawings and/or drive hardware and software manuals for specific wiring instructions. 3. 2 lifting eyes located on the top of the main housing. This means it can fall out if the unit is tipped so that the top is lower than the bottom mounting plate. After removing the bracket holding the rack in place. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 14 of 32 . the rack is free to move (bracket not shown). Below shows 2 lifting eyes on top of the main housing. Eyes are located so the unit will hang vertically.3 Lifting: When lift or hoist equipment is used to lift the equipment and move it to position.Linear Rod Pump – M echanical M anual 2. For the machine weight see the technical specs in this manual or the machine tag on the base of the LRP® unit.LRP ® . Ensure lift or hoist equipment has appropriate tires for the terrain to avoid becoming stuck or tipping over. Use both to lift the unit. The equipment can weigh as much as 6.500 lbs. be careful not to contact overhead wires or other obstacles. This brake will only engage in the case of a failure with the drive safe stop operation. The brake will only engage when the LRP® system is traveling down and exceeds a motor rpm around 2. Remove the brake cover. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 15 of 32 . The torque specs can be found on page 1 or on the white tag on the LRP® unit base for the correct bolt torque. Verify the Torque on the 8 nuts before installing the LRP® unit.3. Check torque of all 8 bolts per tagged requirement. The eight bolts located around the brake are what define the brake torque.LRP ® .4 Brake information: This is a centrifugal brake.Linear Rod Pump – M echanical M anual 2.500rpm. The brake will reset automatically when the unit starts to move upward. 5” over travel in both directions) Proximity switch location between the housing and the gearbox. (2. thread the proximity switch in until it bottoms out on this surface.Linear Rod Pump – M echanical M anual 2.3. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 16 of 32 . -The proximity switch will be made in the middle of the stroke but not at the end of stroke. This will space it off the guide 1/8”. 10” from top and bottom of normal stroke. T hen back it out 5/8” and put a lock nut on it. The slot for the Proximity switch starts 12 ½” from max top and bottom of stroke.LRP ® .5 Proximity switch installation: With the rack in the lowered or parked position. **Put thread sealer on prox to protect against leaks. Insert the polished rod into the LRP® unit prior to lifting. Polished rod. The mounting hardware between the stand and the base are supplied with the machine. A coupling can then be used between the 2 polished rods. There are 2 ways to install the LRP® unit on the well.3. Polished rod. 2.LRP ® . verify that the stand is level. Clamp the rod so that it does not fall out. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 17 of 32 .Linear Rod Pump – M echanical M anual 2.5” outer diameter so that it can fit up into the bottom of the LRP® unit.1 Installing with polished rod in LRP® unit. Rod Clamp. Then lift the LRP® unit over the well and connect the polished rod in the well to the polished rod in the LRP® unit. The coupling must be less than 2.6. Before installing the LRP® unit.6 Installing the LRP® unit on the Well Head.3. 3.2 Install over the polished rod. Top plate is chamfered on the inside. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 18 of 32 .6.Linear Rod Pump – M echanical M anual 2.LRP ® . This requires lifting the unit much higher. nd The 2 way is to install the LRP® unit over the polished rod. Pull the tube away and fill the trap in the tube with oil. This is the lubrication for the rack.3. The oil is under very low pressure. Run the LRP.LRP ® . See page #1 or white tag on the base of the LRP® unit for oil specs and quantity. Check for oil flow at this fitting. While the LRP® unit is running verify the reticulating pump is pumping fluid.3. Oil fill port for base Oil full sight glass when rack is in the lowered or parked position. and bearings.7. pinions. Oil should steadily run out around the fitting. To do this. Reconnect the tube and fitting. 2. Prime the pump in this location. Leave the fitting loose to check for oil. The pump will pump in both direction (upstroke and down stroke). Reconnect the bottom tube and fitting.7 Fill the unit with oil. Remove the fitting from the bottom of the pump.Linear Rod Pump – M echanical M anual 2. Remove the fitting on the top of the pump and add some oil into the top of the pump. The LRP® unit has 2 oil reservoirs. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 19 of 32 . The unit is shipped WITHOUT oil. simply loosen the fitting on the output side of the pump.1 Base fill port. The unit must be filled at installation. Oil should steadily run out around the fitting. 7.2 Gearbox: There are 2 different gearbox suppliers used on the LRP® units. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 20 of 32 .3. Sight glass for gearbox fill level. Fill port for gearbox.LRP ® . Verify which gearbox is on your unit.Linear Rod Pump – M echanical M anual 2. This may be supplied with oil from the factory and must be checked. Below is the fill ports and site glass for the Bonfiglioli Gearbox. Bonfiglioli name on the side of the gearbox. LRP ® .Linear Rod Pump – M echanical M anual Below are the fill ports for the SEW gearboxes. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 21 of 32 . Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 22 of 32 . This will change the amount of rotation the rotator moves each stroke.8 Optional rod rotator: The rod rotator turns the rod string a set amount every stroke. After the LRP® unit is installed on the well head set the rotator on top of the plate in the machined pocket. Be careful not to drop parts into the gearing if changing position of the roller. Use the lower 2 roller holes to change the amount the rotator moves. If every thing is cycling good then put the top cover on. The rod will go thought the center and the rod clamp will set on top of the rotator. Rod clamp sits on top of rod rotator. Rod rotator sits in the pocket in top plate. (SAE 20 recommended for the model T-252) Roller can be used in either of the lower 2 holes. It is recommended that you run the LRP® unit at this point with the top cover off and watch the rod rotator cycle. Fill with light oil to bottom of plug hole.LRP ® . Rod clamp not shown.Linear Rod Pump – M echanical M anual 2.3. 4.Linear Rod Pump – M echanical M anual 2.9 Top cover installation: The mounting hardware is supplied with the machine. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 23 of 32 . Seal the top cover to the housing with Loctite gasket sealant number 2 or equivalent.LRP ® . See section 3.3. 6. If a leak is detected. and Rod Rotator. These checks are not required before each start. the following checks must be performed before starting the unit. The post mechanical installation checks are now complete. After the operation checks are made. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 24 of 32 . several checks must be made: a.3. Ensure all covers are in place and be sure no hands are inside the equipment when it starts. b. With the unit running.4 and 3. only after the initial installation. 4. stop the unit (move the Equipment switch to the “Off” position). Re-check unit oil levels. immediately stop the unit (move the equipment switch to the “Off” position) and repair the leak before proceeding. Verify there are no oil leaks.Linear Rod Pump – M echanical M anual 2. Verify unit oil levels are full.2. Section 2. If vibrations or other sources of noise exist. 1.3. Gearbox. Verify that the brake bolts were set to the correct torque.LRP ® . Close all covers. Verify that the operation is smooth. Base. 2. 3. immediately stop the unit (move the Equipment switch to the “Off” position) and repair/adjust before proceeding.10 Post Installation Checks: When the initial installation is complete. 5. 000hours or 6 months. 2.1 Gearbox oil: Bellow is a recommended oil change interval based on temperature for the gearbox. There are 2 methods of lubrication on the LRP® system rack. The pinion housing is divided in 2 areas.6 for fill instructions.1. Oil bath. This pump pumps oil in both directions. As oil is pumped into this reservoir the oil reaches the center bearings and drains through them back into the base. This pump sends oil into the slitter gear side of the pinion housing to lubricate the outer bearing.6 times as fast as the pinion. the splitter gear side and the rack side. During the up stoke oil is transferred to the pinions and splashed on the bearings.2 Rack and Pinion oil Change every 4. It is driven off the splitter gear.LRP ® 3 . 3. The rack sits in a bath of oil when in the down position. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 25 of 32 . pinions and bearings. Lubrication pump.1. It is rotating 4. The splitter gear side is a small reservoir. M obilgear 600XP 220 is a mineral based oil. 3. 1.Linear Rod Pump – M echanical M anual Maintenance: Ensure the machine is properly Locked Out prior to any maintenance. 3.1 Oil Change: Find the oil type and quantity on page #1 of this manual or the white machine tag at the base of the LRP® unit. See Section 1. LRP ® .Linear Rod Pump – M echanical M anual Splitter gear side of the housing. Rack and Pinion side of the housing. Showing the internal lubrication lines. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 26 of 32 . Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 27 of 32 . There are two drain locations for the base.LRP ® . There are 2 locations to drain oil from the base of the LRP unit.Linear Rod Pump – M echanical M anual 3.1.2 Draining oil from the LRP® unit. Both of these locations need to be drained when changing oil in the base. Resetting the brake once engaged. Example: If power is lost only a few inches from bottom. How does it work? The brake is a centrifugal mechanical brake. Remove 5 bolts then slide cover off. Do not operate the LRP® system with out the brake installed and properly set. The brake disc is sandwiched between brake pads. Remove the brake cover: The cover can be removed from the brake as shown below.2 Brake: This Brake is only used in the event the drive can not park the rack on bottom because of an unforeseen failure in the drive system. You are now ready to run. Because the brake requires a certain rpm before it engages there is the potential for the LRP® system to bottom out before the brake can set. The more torque the more stopping power. To release the brake simply stroke the unit up a few inches and the brake will retract.Linear Rod Pump – M echanical M anual 3. The amount of stopping force the brake has is determined by the torque on the 8 bolts holding the brake assembly together. The LRP® system start up routine will automatically do this for you automatically. The cover should remain on the machine to keep out the weather and debris after maintenance is completed.LRP ® . Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 28 of 32 . In this case there is a bumper in the base of the LRP® unit to absorb this impact. The brake will only engage on the down stroke. Once the brake hub exceeds a set rpm the centrifugal force expands and engages with the brake disc. This brake will only engage in one direction (down stroke). 75 2. In the event you need the brake to engage sooner or later you should consult the manufacturer. 5 0. Example: 2500 motor rpm / 19. There is some variation from spring to spring so the chart below is for the nominal.21 1 0. 5 0.0 63 2.05 4 2 0. Springs Ge arb ox Brake Ratio: RPM Spring part number: Z A 9.LRP ® .99 1 0.0 63 2.8 70 McMaster Carr # 90 65K375 Contact Information: UNICO: 262-886-5678 # of springs on p ost locatio n Spring Locat ion : Tota l # of sprin gs: AAAAA- C C B B B High Production Technology : 419-592-0050 OD Wire Ø: L ength Sp ring rate: in in in lbs/in 4 4 0.4 29.5 2.6 250 200 Lee Spring #L E 067E 06 S McMaste r Carr # 9 432K91 B C D 19.99 7. 5 0.0 63 0.38 ratio = 127 rpm required at the brake.99 Printed on 11/14/2011 Page 29 of 32 . 5 0.75 7.75 7. See chart for spring combinations.Linear Rod Pump – M echanical M anual Engagement rpm: The required rpm is determined by the max motor rpm (+/-10%) / the gearbox ratio.0 63 2. This rpm is then achieved by using springs to overcome the centrifugal force until that given rpm.5 1 2.7 12. 5 0.1 125 90 McMaster Carr # 90 65K375 McMaster Carr # 90 65K375 35.0 67 0. When tightening the nuts the first time around alternate sides when moving from nut to nut. The proper brake torque can be found in the technical spec section or the white machine tag on base of the LRP® unit. or after every 10 brake engagements. There are 8 nuts (2 in each corner) on the brake that need to be checked.Linear Rod Pump – M echanical M anual Brake torque: The brake torque is set by the torque on the 8 nuts on the outside of the brake.LRP ® . These nuts should be checked periodically for the correct torque (every 6 months). After you have tightened them all once then recheck all the nuts for torque again. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 30 of 32 . You will need a 1 7/16" socket and a torque wrench. Repeat this process until the nuts do not move under the specified torque. 5. 2. viscous paste with a characteristic alcohol odor. The product can be removed from metal surfaces with isopropyl alcohol.3 Bolt Torque: Use the torque table below for all fasteners.000 Nominal Dia. DIRECTIONS FOR USE 1. Slower drying formula increases work time. full cure is affected aft er 24 hours. If the sealant has been dried for a long time or at high temperatures. connections and flexible assemblies against leakage. • Use Loctite #243 Blue M edium Strength thread locker on all fasteners. 2.000 5/8-1" 170. 3.Linear Rod Pump – M echanical M anual 3. Lubricate all contact areas of the bolts and washers. Lubricating the bolts is the suggested method.4 Sealing mating surfaces oil tight: • Use LOCTITE® Gasket Sealant #2 or equivalent to seal all mating surfaces oil tight. It seals flanges.000 150. For best results. clean and dry all surfaces with a residue-free solvent 3. Assembly is operational after 4 hours. It increases the reliability of gasket seals. Coat the second side of gasket and re-assemble.LRP ® . puncture tube or cartridge seal and attach extension nozzle (i f provided). Remove all previous material from mating surfaces. and Bolt Torque Specs in Foot Pounds or (Inch Pounds) Thread Pitch Dry Lubed Dry Lubed Dry Lubed 1/4-20 (101) (76) (143) (107) (168) (120) 3/8-16 (372) (276) 44 33 51 38 7/16-14 49 37 70 52 81 61 1/2-13 75 57 106 80 124 93 5/8-11 150 113 212 159 238 179 3/4-10 267 200 376 282 423 317 Lubed means cleaned dry bolts lubricated with a standard medium viscosity machine oil. flexible setting paste that changes to a pliable. It is a slow drying. Bolt Torque Table Estimated with clamp load as 75% of proof load as specified in SAE J429 and ASME 574 SAE 5 SAE 8 Socket Head Cap Screws Steel Grade Minimum Tensile 1/4-1/2" 180. 4. When used as a gasket dressing. For Cleanup 1. cover the seal ant with alcohol and allow to soften overnight.000 Strength PSI 120. Clean hands with hand cleaners. non-hardening film through solvent evaporation. Please see the brake section for the torque on the brake nuts. Remove cap. LOCTITE® Gasket Sealant #2 is a black. spread product with a spatula to a uniform film on one side of gasket and then position it on the assembly. fittings. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 31 of 32 . 6 Spare / replacement parts: .3. See Section 2.A mechanical parts list was supplied with the LRP® unit please refer to it for and spare or replacement parts. a. Remove the cam follower blocks one at a time to inspect the cam followers. a. Check the brake bolt torque as described in section 2. Visual inspection of pinions. Visually check oil level at the sight glass in LRP® unit stand. and dirt. Contact Information: UNICO: 262-886-5678 High Production Technology : 419-592-0050 Printed on 11/14/2011 Page 32 of 32 .3.When inquiring about spare parts please have the model and serial number of the LRP® unit. a. Look for worn. 2. See section 2. . 3. grease. Visually check for oil leaks from sealed surfaces and fittings.3. Perform general clean up of oil.4 and 3. rack. During the brake inspection.7 3. These can be found on the white machine tag at the base of the LRP® unit. See section 3. Yearly: 1.2. Check and verify lubrication oil is be pumped. and gears through housing inspection covers. Remove any debris from the brake.Linear Rod Pump – M echanical M anual 3. Reseal the mating surfaces when reassembling the blocks. Change oil in LRP® unit base for rack and pinions. Check for excessive wear on gear teeth. a. There are 4 locations. Six Months: 1.7 2. This will need to be checked as the unit is running.5 Preventative Maintenance schedule: Weekly: 1. Change oil in Gearbox. broken or missing part. 5.3. See section 2.LRP ® .7.4 3. 4.