Manual Unidades LRP

LRP® - Linear Rod Pump – Mechanical Manual
Linear Rod Pump Systems
IMPORTANT!!!
Read this manual prior to
Installation.
MECHANICAL INSTALLATION AND MAINTENANCE MANUAL
Manual # 2.0.8
Contact Information: UNICO: 262-886-5678 High Production Technology: 419-592-0050 Printed on 12/7/2012 Page 1 of 33
TECHNICAL SPECS: ....................................................................................................................... 3

SAFETY INFORMATION ............................................................................................................... 5
OVERVIEW ........................................................................................................................................ 5
CONVENTIONS USED ......................................................................................................................... 6
GENERAL PRECAUTIONS ................................................................................................................... 6
INSTALLATION PRECAUTIONS ........................................................................................................... 7
MAINTENANCE PRECAUTIONS .......................................................................................................... 8
EQUIPMENT CONTROL PRECAUTIONS............................................................................................... 9
SAFE SERVICE PRACTICES ................................................................................................................ 9
2 INSTALLATION .......................................................................................................................... 11
2.1 OVERVIEW................................................................................................................................ 11
2.2 INSTALLATION GUIDELINES .................................................................................................... 11
2.2.1 Long Term Storage ........................................................................................................... 11
2.2.2 Site Planning .................................................................................................................... 11
2.2.2.1 Stand .......................................................................................................................... 11
2.2.3 Unloading………………………………………………………………………………..13
2.3 INSTALLATION.......................................................................................................................... 14
2.3.1 Electrical Connections ..................................................................................................... 14
2.3.2 Retracted Unit Height: ..................................................................................................... 14
2.3.3 Proximity switch installation prior to start-up: ............................................................... 15
2.3.4 Installation hoisting procedure: ...................................................................................... 16
2.3.6 Installing the LRP® unit on the Well Head. ................................................................... 17
2.3.6.1 Installing with polished rod in LRP® unit. ............................................................ 18
2.3.6.2 Install over the polished rod. ................................................................................... 19
2.3.7 Fill the unit with oil. ......................................................................................................... 20
2.3.7.1 Base fill port. ............................................................................................................. 20
2.3.7.2 Gearbox: .................................................................................................................... 21
2.3.8 Optional rod rotator: ........................................................................................................ 23
2.3.9 Top cover installation:...................................................................................................... 24
2.3.10 Post Installation Checks: ............................................................................................... 25
3 MAINTENANCE: ......................................................................................................................... 26
3.1 OIL CHANGE: ........................................................................................................................... 26
3.1.1 Gearbox oil: ...................................................................................................................... 26
3.1.2 Rack and Pinion oil .......................................................................................................... 26
3.1.2 Draining oil from the LRP® unit. ................................................................................... 28
3.2 BRAKE: ..................................................................................................................................... 29
3.3 BOLT TORQUE: ........................................................................................................................ 32
3.4 SEALING MATING SURFACES OIL TIGHT: ................................................................................. 32
3.5 PREVENTATIVE MAINTENANCE SCHEDULE: ........................................................................... 33
3.6 SPARE / REPLACEMENT PARTS: ............................................................................................... 33
Technical Specs:
(Verify this info with the tag on the machine)
Model #: ___________________________________
Serial #: ____________________________________
Gear ratio: __________________________________

Tag location
Actual brake engagement RPM:_________________ at the base
of the LRP.
*Max Motor RPM = Brake engagement RPM x Ratio -100
Lifting capacity: 30,000 lbs
Linear Lead (one turn of the pinion): 18.8495 in/rev
Max torque setting (gearbox output torque): 90,000 in-lbs
Brake: Bolt torque: 75 ft-lbs (8 places)
Type of oil: Mobilgear 600xp 220 or synthetic equivalent. This lubricant is rated for -20 to +80
degrees Celsius. (The lubricant must be rated for the temperature range it will operate in.)
Rated Stroke: (inches) 86 100 120

Total Stroke: (inches) 89.25 101.5 121.5
Rack and guide weight: (lbs) 1260 1395 1588
LRP weight without oil: (lbs) 5250 5750 6250
Retracted Unit Height: (inches) 130.5 144.5 164.5
Over all height above stand: (inches) 275.5 299.5 339.5
Overall height above stand with rod rotator: (inches) 280.25 304.25 344.25
Gearbox oil capacity: (gal ) 10.3 10.3 10.3
Base oil capacity: (gal) 20 22.5 26.1
Model number example:
L=LRP RATIO: STROKE: REVISION

NUMBER:
MOTOR FRAME: OPTIONS:
RR=ROD ROTATOR
TORQUE VALUE:
Customer information:
Well location: ______________________________________________________
Well No.: _________________________________________________________
Install Date: _______________________________________________________
__________________________________________________________
Notes:
_______________________________________________________________
_______________________________________________________________
Rod rotator option:

Top cover
Guide roller
Brake
Gearbox
Pinion
Pinion housing
Motor
Rack
Base
Stand
Safety Information
Overview
This section states important safety information that must be followed when setting up, operating,
and troubleshooting this equipment. Study this information carefully before working with this
equipment, as failure to follow these instructions may lead to personal injury or death, or
damage to the unit, drive, motor, and/or driven equipment. Installation and repair procedures
require specialized skills with mechanical pumping systems. Any person that installs or
repairs this unit must have these specialized skills to ensure that it is safe to operate. Contact
the Unico, Inc. service department for repairs or any questions you may have about the safe
installation and operation of this system. The precaution statements are general guidelines for the
safe use and operation of this LRP® system. It is not possible to list all unsafe conditions. Therefore
if you use a procedure that is not recommended in this manual, you must determine if it is safe for
the operator and all personnel in the proximity to the unit. If there is any question of the safety of a
procedure, please contact Unico, Inc before starting.
This equipment contains high voltages. Electrical shock can cause serious or fatal injury. Only
qualified personnel should attempt startup or troubleshoot this equipment. This equipment has
moving parts. Improper use can cause serious or fatal injury. Only qualified personnel should
attempt startup or troubleshooting of this equipment.
 System documentation must be available to anyone that operates this equipment at all times.
 Keep non-qualified personnel at a safe distance from this equipment.
 Only qualified personnel familiar with the safe installation, operation and maintenance of
this device should attempt startup or operating procedures.
 Always disconnect power before making or removing any connections.
 Always ensure any connected equipment capable of falling is safely secured by approved
methods prior to working on this unit.
When your LRP® unit is delivered, it becomes the responsibility of the owner/operator of the unit
to provide safe conditions and operation of the equipment. Some responsibilities include (but are
not limited to) the following:
1. It is the responsibility of the owner/operator of this equipment to ensure that it is correctly

and safely installed.
2. It is the responsibility of the owner/operator of this equipment to ensure that it, when
installed fully, complies with all federal, state and local codes.
3. It is the responsibility of the owner/operator of this equipment to ensure that any person
operating it has been properly trained.
4. 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.
5. 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.
6. 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.
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, property damage, or economic loss.
General Precautions
Never operate this unit in a manner other than as described in this manual. Operation in any
manner not described in this manual should be considered unsafe and should not be
attempted. Never start the equipment unless you have first verified that the installation
and operation are as described in this manual.
Be sure that you are completely familiar with the safe operation of this equipment. This
equipment may be connected to other moving parts. Improper use can cause serious or fatal
injury.
Some parts of this unit move during operation. Rotating parts can present extreme danger if
clothing or body extremities are caught by the rotating part and can cause serious or fatal
injury. Never touch a part of the equipment until all moving parts are completely stopped.
Also, all electrical power must be removed to prevent accidental movement during
servicing.
Be sure that you understand how to stop the unit quickly in case of an emergency situation.
Become familiar with the controls and safety systems provided with this equipment.
Improper operation may cause violent motion of connected equipment. Be certain that
unexpected movement will not cause injury to personnel or damage to equipment.
Never permit anyone to operate the equipment without proper instructions. Be sure to keep a
copy of this manual with the unit so that all users can be properly informed of its safe
operation.
Never allow children or pets to be in the area where the equipment is running. The unit may
cause injury or death.
Never operate the equipment unless all guards, covers, shields and other safety items are
properly installed.
Do not put hands, feet, tools clothing or other objects near moving parts. Moving parts cause
extremely dangerous situations because they can catch loose clothing or extremities and
cause serious or fatal injury.
When operating this equipment remain alert at all times. Never operate machinery when
physically or mentally fatigued, or while under the influence of alcohol, drugs or
medication.
High voltage is present whenever the equipment is running. Electrical shock can cause
serious or fatal injury. Never operate electrical equipment while standing in water, on wet
ground or with wet hands, feet or shoes or while barefoot.
Installation Precautions
Installation and repair procedures require specialized skills with electrical equipment and
mechanical pumping systems. Any person that installs or performs repairs must have these
specialized skills to ensure that the unit is safe to operate. Contact Unico, Inc. for installation
or repairs.
Be sure all wiring complies with the National Electrical Code (NEC) and all regional and
local codes or CE Compliance. 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. Do not apply AC power
before you ensure that grounds are connected. Electrical shock can cause serious or fatal
injury. NEC requires that the frame and exposed conductive surfaces (metal parts) be
connected to an approved earth ground. Local codes may also require proper grounding of
equipment systems.
Place protective covers over all moving parts such as motor shaft and fan, gearing, etc.
Moving parts cause extremely dangerous situations because they can catch loose clothing or
extremities and cause serious or fatal injury.
Unauthorized modification of equipment may make the unit unsafe for operation or may
impair the operation of the unit. Never start a unit that has been modified or tampered with.
Be sure that all covers and guards are properly installed and that the unit is safe before
starting. If you are unsure, contact Unico, Inc.
When moving the equipment, use reasonable caution. Be careful where you place fingers
and toes to prevent injury. Never try to lift equipment without an appropriate hoist or
lifting means, as it is heavy and bodily injury may result.
Circuit overload protection must be provided in accordance with the National Electrical
Code and local regulations.
Have electrical circuits and wiring installed and checked by licensed electrician or qualified
technician. Electrical shock can cause serious or fatal injury.
Maintenance Precautions
Disconnect all electrical power before servicing the equipment. Electrical shock can cause
serious or fatal injury. Always treat electrical circuits as if they are energized.
Before cleaning, inspecting, repairing or performing any maintenance to the equipment,

always be sure the unit has stopped and that all moving parts have also stopped. After
stopping, certain components may retain significant potential energy due to gravity. Ensure
all loads are properly secured to prevent accidental motion.
Inspect all wiring frequently and replace any damaged, broken or frayed wiring or wires
with damaged insulation immediately. Electrical shock can cause serious or fatal injury.
Disconnect all electrical wires and load devices from equipment power outlets before
servicing the equipment. Electrical shock can cause serious or fatal injury. Always treat
electrical circuits as if they are energized.
Use only original equipment or authorized replacement parts. Using the correct parts will
assure continued safe operation as designed.
Do not lift the equipment from the motor lifting eyes. These points are not designed for
the weight or lifting angle needed for the LRP® unit.
Equipment Control Precautions
An incorrectly installed or operated drive can result in damage to the equipment it controls.
Make certain installation and operating specifications are followed.
Control inputs do not generate an emergency stop of the motor and do not remove electrical
power that can cause hazardous conditions. Regardless of the operating state, the drive’s
motor output terminals may be at dangerous voltage levels whenever input power is applied
and the bus is charged.
The LRP® unit may start automatically whenever power is applied or after a fault trip if the
auto restart has been enabled. The restart function must not be enabled when hazardous
conditions might arise from such action.
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
1 About this Manual

1.1 Overview
This chapter describes the contents and intended audience of this document.
1.2 Contents
This manual provides the instructions and technical information necessary to complete the
mechanical installation of the LRP® unit.
1.2.1 What’s Covered

• Safety Information, discusses safety hazards and precautions important to anyone working
with this equipment.
• Chapter 1, About this Manual, Overview of this document.
• Chapter 2, Installation, describes the installation of the Unico LRP® system.
• Chapter 3, Maintenance, describes the maintenance of the Unico LRP® system.
1.2.2 What’s Not Covered

This manual does not address basic hardware and firmware aspects of the drive. These
topics are covered in the drive installation and firmware instruction manuals. Please refer to
those documents for:
• Unpacking and receiving instructions
• Hardware features and specifications
• Electrical installation instructions
• Drive troubleshooting, maintenance, and spare parts
• Detail listing of basic drive parameters
• Drive setup and auto tuning procedures
• Interface setup and diagnostic utilities
1.3 Intended Audience

This manual is intended for anyone who will be installing, operating, and servicing the
LRP® system. Installation should be performed by qualified personnel to ensure that correct
practices and applicable codes are applied. Start-up and operation should be performed by
personnel familiar with both the drive and the machinery or equipment interfaced.
The audience is expected to have a basic knowledge of physical and electrical fundamentals,
electrical wiring practices and components, and electrical schematics.
Follow instructions
You can help prevent injury and damage to the drive or equipment by carefully
following the procedures outlined in this manual.
Follow regulations
All electrical work should conform to the National Electrical Code as well as all state and
local government regulations. 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. Consult with the factory if unsure on any topic before
proceeding.
1.4 Intended Application

Unico LRP® systems are intended for vertical rod pump applications. This unit must be
operated in the manner prescribed by this document. Uses outside those prescribed shall
invalidate the manufacturer’s warranty.
2 Installation
2.1 Overview
These operating instructions are intended to help you install and operate the LRP® unit. For
trouble free service, proper installation and operation are essential. Additionally, these
instructions contain important recommendations on maintenance. Before shipment, every LRP®
unit is checked and properly packed. However, please inspect the unit immediately upon arrival
for shortage or transit damage. Note the damage or shortage on the freight bill of lading and file
a claim with the carrier. Also, notify UNICO of the shortage or damage.
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 Municipality/City/County and
State/Province.
 National Fire Protection Association

o No. 30 – Storage, Handling and Use of Flammable Liquids.
 Local Codes applicable to mechanical equipment installation. See your local building
inspector.
NFPA (National Fire Protection Association)

(617) 770-3000 (includes NEC), 1 Batterymarch Park, Quincy, MA 02169-7471 USA
2.2.1 Long Term Storage

If the unit is not installed immediately, it should be stored in a dry, protected area. Units which
are used for standby service should be stored sealed.
2.2.2 Site Planning

This equipment system once properly installed is enclosed and is designed for outdoor use. The
following sections provide guidelines for successful installations.
2.2.2.1 Stand
• The unit is intended for mounting on a Unico mounting stand that is supported by a casing or
tubing flange. This stand must be installed so that is concentric and perpendicular to the
polished rod.
• It is the user’s responsibility to ensure there is adequate integrity of the well completion for the
gas and fluid flow when the stand is installed.
• Important: Ensure the stand is concentric and perpendicular to the

polished rod. Appropriate shims or adjustments to the mounting stand may
be necessary. Failure to do so could result in premature wear of stuffing box
and/or LRP®
CENTER HOLE
IN TOP OF
STAND SHOULD
BE CONCENTRIC
TO POLISHED
ROD WITHIN 1/8”
90° ± 1°
UNICO
STAND
2.2.3 Unloading:
When using forklift or hoist equipment to unload the LRP® unit when it arrives on site, be
careful not to contact overhead wires or other obstacles. The equipment can weigh as much as
6,500 lbs. Ensure lift or hoist equipment has appropriate tires for the terrain to avoid becoming
stuck or tipping over. For the machine weight see the technical specs in this manual or the
machine tag on the base of the LRP® unit.
Do not remove steel banding straps from shipping stand/LRP® until unit is unloaded from
truck and positioned near well site for final installation.
The internal rack assembly is retained in the unit with a steel shipping strap. Care should be
taken to avoid tipping the top end of the unit below horizontal once this strap is removed as
gravity could allow the rack to travel out the end.
2.3 Installation
The equipment is assembled, and adjusted at the factory before it is shipped. It is the
responsibility of the Owner/Operator to arrange for the procedures in this manual to be
performed by licensed contractors according to all applicable codes including local codes
for your Municipality/City/County and State/Province.
Important: When installing this unit it is important to keep any and all debris from falling
into the top of the unit. The top of the unit is open until the top cover is installed. If debris falls
into the opening and into the gear teeth it can cause a major failure of the gearing.
2.3.1 Electrical Connections

Consult supplied electrical drawings and/or drive hardware and software manuals for specific
wiring instructions.
2.3.2 Retracted Unit Height:
Retracted unit
height is from the
top of the stand to
the top surface of
the rod clamp
block.
Note:
Use this to dimension to determine the height of the polished rod. This dimension can be found in
the technical specs of this manual. The polished rod should not protrude more than 45” above
this dimension. At rated stroke there will be at least 45” clearance between the rod clamp surface
and the inside of the top cover.
2.3.3 Proximity switch installation prior to start-up:

The proximity switch can be installed on the unit prior to removal from the shipping stand.
Failure to adjust switch per drawing below could result in the switch being sheared off
at start-up.
With the rack in the lowered or

parked position, thread the
proximity switch in until it
bottoms out on this surface
then back it out 5/8” and
tighten lock nut. This will space
it off the guide 1/8”. **Put
thread sealer on prox to protect
against leaks.
5/8”
½” deep pocket at both ends of

stroke is used during start up Proximity switch
routine to generate a reference
signal to confirm proper stroke
location
during operation.
2.3.4 Installation hoisting procedure:

Remove steel banding straps securing LRP® components to shipping stand and slide top
rack cover out of the way of LRP® base flange.
Remove cross Integral hoisting eyes (2)

bar from cradle
Attach two equal length hoist chains/straps to integral hoisting eyes on LRP® and
slowly lift/tip unit to vertical position.
2.3.6 Installing the LRP® unit on the Well Head.

Important: When installing this unit it is important to keep any and all debris from falling into
the top of the unit. The top of the unit is open until the top cover is installed. If debris falls into the
opening and then into the gear teeth it can cause a major damage to the gear train.
Before installing the LRP® unit, verify that the Unico stand is centered and aligned with the
polished rod as it exits the stuffing box (refer to 2.2.2.1). The mounting hardware between the stand
and the base are supplied with the machine.
There are 2 ways to install the LRP® unit on the well depending on polished rod configuration and
available hoisting equipment.
Whichever way is used, while setting unit on stand, shift as required prior to tightening fasteners to
center the base of LRP® such that the polished rod is concentric within 1/8” where it enters
the central tube of the LRP®. Failure to do so could result in premature wear of stuffing box
and/or LRP®.
Central tube of LRP®
Polished rod
A convenient way to check for
concentricity is to insert a
socket of appropriate diameter
into gap to check for equal
clearance around polished rod.
2.3.6.1 Installing with polished rod in LRP® unit.

Insert the polished rod into the LRP® unit prior to lifting. Clamp the rod so that it does not fall
out. Then lift the LRP® unit over the well and connect the polished rod in the well to the
polished rod in the LRP® unit with a coupling. The coupling must be less than 2.5” outer
diameter so that it can pass safely into the bottom of the LRP® unit.
Polished rod.
Rod clamp.
2.5” max
diameter
polished rod
coupling
Polished rod.
2.3.6.2 Install over the polished rod.

This requires lifting the unit high enough so that it can then be lowered over the exposed
polished rod.
Top plate is chamfered on the inside

thus rod will thread itself through.
2.3.7 Fill the unit with oil.
The unit is shipped WITHOUT oil. The unit must be filled at installation.
The LRP® unit requires oil in both the base unit and the gearbox.
See page #3 or white tag on the base of the LRP® unit for oil specs and quantity.
2.3.7.1 Base fill port.

This is the lubrication for the rack, pinions, and bearings.
Oil fill port for

Base unit
Oil full sight

glass when rack
is in the lowered
or parked
position.
At initial LRP® start-up, verify the reticulating pump is pumping fluid. To do this, simply loosen
the fitting on the output side of the pump (see drawing below). Oil should steadily run out around
the fitting while in operation. If no flow is detected within a couple minutes after initial start-up, it
will need to be primed per drawing below.
Check for oil flow at this fitting. The oil is

under very low pressure.
Prime the pump in this location. Remove the

fitting from the bottom of the pump. Pull the tube
away and fill the trap in the tube with oil.
Reconnect the bottom tube and fitting. Remove
the fitting on the top of the pump and add some oil
into the top of the pump. Reconnect the tube and
fitting. Leave the fitting loose to check for oil. Run
the LRP. Oil should steadily run out around the
fitting.
2.3.7.2 Gearbox:
There are 2 different gearbox suppliers used on the LRP® units. Verify which gearbox is on your
unit. Bonfiglioli brand gearboxes are shipped without oil however some SEW brand gearboxes
are supplied with oil from the factory and must be checked.
Below are the fill ports and site glass for the Bonfiglioli Gearbox.
Sight glass for

Fill port for Bonfiglioli gearbox
Bonfiglioli
gearbox.
Bonfiglioli name on the

side of the gearbox.
Below are the fill ports for the SEW gearboxes.
2.3.8 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. The rod will go
thought the center and the rod clamp will set on top of the rotator. Use the lower 2 roller holes to
change the amount the rotator moves.
It is recommended that you run the LRP® unit at this point with the top cover off and watch
the rod rotator cycle. If every thing is cycling good then put the top cover on.
Rod clamp sits on top of

rod rotator. Rod clamp
not shown.
Fill with light oil to bottom

of plug hole. (SAE 20
recommended for the model
T-252)
Roller can be used in either of the

lower 2 holes. This will change the
amount of rotation the rotator
moves each stroke. Be careful not
to drop parts into the gearing if
changing position of the roller.
Rod rotator sits in the

pocket in top plate.
2.3.9 Top cover installation:

The mounting hardware is supplied with the machine.
Seal the top cover to

the housing with
Loctite gasket sealant
number 2 or
equivalent. See section
3.4.
2.3.10 Post Installation Checks:

When the initial installation is complete, the following checks must be performed before starting
the unit. These checks are not required before each start, only after the initial installation.
1. Verify unit oil levels are full. Base, Gearbox, and Rod Rotator (if equipped with one).
2. Verify that the brake bolts were set to the correct torque. Section 3.2.
3. Ensure all covers are in place and be sure no hands are inside the equipment when it starts.
4. With the unit running, several checks must be made:
a. Verify there are no oil leaks. If a leak is detected, immediately stop the unit (move
the equipment switch to the “Off” position) and repair the leak before proceeding.
b. Verify that the operation is smooth. If vibrations or other sources of noise exist,
immediately stop the unit (move the Equipment switch to the “Off” position) and
repair/adjust before proceeding.
5. After the operation checks are made, stop the unit (move the Equipment switch to the “Off”
position). Re-check unit oil levels.
6. Close all covers. The post mechanical installation checks are now complete.
3 Maintenance:
Ensure the machine is properly Locked Out prior to any maintenance.
3.1 Oil Change:

Find the oil type and quantity on page #3 of this manual or the white machine tag at the base of the
LRP® unit.
See Section 2.3.7 for fill instructions.
3.1.1 Gearbox oil:

Below is a recommended oil change interval based on temperature for the gearbox.
Mobilgear 600XP 220 is a mineral based oil.
3.1.2 Rack and Pinion oil

Change every 4,000hours or 6 months.
There are 2 types of lubrication utilized on the LRP® system rack, pinions and bearings.
1. Oil bath. The rack sits in a bath of oil when in the down position. During the up stoke oil is
transferred to the pinions and splashed on the bearings.
2. Lubrication pump. It is driven off the splitter gear. It is rotating 4.6 times as fast as the pinion.
This pumps primary purpose is to send oil into the splitter gear side of the pinion housing to
lubricate the outer bearings. It also provides extra lubrication to pinion gears. The pinion housing is
divided in 2 areas, the splitter gear side and the rack side. The splitter gear side is a small reservoir.
As oil is pumped into this reservoir the oil reaches the center bearings and drains through them back
into the base.
Splitter gear side

of the housing.
Rack and Pinion side

of the housing.
Internal lubrication lines
3.1.2 Draining oil from the LRP® unit.
There are 2 locations to drain oil from the base of the LRP unit. Both of these locations need to be
drained when changing oil in the base.
Two drain locations

for the base.
3.2 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.
How does it work?

The brake is a centrifugal mechanical brake. This brake will only engage in one direction (down
stroke). Once the brake hub exceeds a set rpm the centrifugal force expands and engages with the
brake disc. The brake disc is sandwiched between brake pads. The amount of stopping force the
brake has is determined by the torque on the 8 bolts holding the brake assembly together. The more
torque the more stopping power.
Do not operate the LRP® system with out the brake installed and properly set.
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. Example: If power is lost only a few inches from the
bottom of the stroke. In this case there is a bumper in the base of the LRP® unit to absorb this
impact.
Resetting the brake once engaged. The brake will only engage on the down stroke. To release the
brake simply stroke the unit up a few inches and the brake will retract. You are now ready to run.
The LRP® system start up routine will do this for you automatically.
Remove the brake cover:

The cover can be removed from the brake as shown below. Remove 5 bolts then slide cover
off. The cover should remain on the machine to keep out the weather and debris after maintenance
is completed.
Engagement rpm:
The required rpm is determined by the max motor rpm (+/-10%) / the gearbox ratio.
Example: 2500 motor rpm / 19.38 ratio = 127 rpm required at the brake.
This rpm is then achieved by using springs to overcome the centrifugal force until that given
rpm. See chart for spring combinations. There is some variation from spring to spring so the
chart below is for the nominal. In the event you need the brake to engage sooner or later you
should consult the manufacturer.
A B
C
B
Springs
Gearbox Brake # of springs on post location OD Wire Ø: Length Spring rate:
Ratio: RPM Spring part number: Spring Location: Total # of springs: in in in lbs/in
Z 9.7 250 Lee Spring #LE 067E 06 S A- C 4 0.5 0.067 2.5 12.21
A 12.6 200 McMaster Carr # 9432K91 A- C 4 0.5 0.063 2.5 10.05
B 19.4 125 McMaster Carr # 9065K375 A-B(3), A-C(1) 4 0.5 0.063 2.75 7.99
C 29.1 90 McMaster Carr # 9065K375 A- B 2 0.5 0.063 2.75 7.99
D 35.8 70 McMaster Carr # 9065K375 A- B 1 0.5 0.063 2.75 7.99
Brake torque:
The brake torque is set by the torque on the 8 fasteners on the outside of the brake. The
proper brake torque can be found in the technical spec section on page three and on the
white machine tag on base of the LRP® unit. You will need a 1 7/16" socket and a torque
wrench. These nuts should be checked periodically for the correct torque (every 6 months),
or after every 10 brake engagements.
There are 8 nuts (2 in each corner) on the brake that need to be checked. When tightening
the nuts the first time around alternate sides when moving from nut to nut. After you have
tightened them all once then recheck all the nuts for torque again. Repeat this process until
the nuts do not move under the specified torque.
8 PLACES
3.3 Bolt Torque:
Use the torque table below for all fasteners. Please see the brake section for the torque on the
brake nuts.
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" 180,000
Strength PSI 120,000 150,000 5/8-1" 170,000
Nominal Dia.
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
Use Loctiteoil.#243
Lubricate
BlueallMedium
contact areas of thethread
Strength bolts and washers.
locker Lubricating
on all fasteners.
the bolts is the suggested method.
3.4 Sealing mating surfaces oil tight:

 Use LOCTITE® Gasket Sealant #2 or equivalent to seal all mating surfaces oil tight.
LOCTITE® Gasket Sealant #2 is a black, viscous paste with a characteristic alcohol odor. It
is a slow drying, flexible setting paste that changes to a pliable, non-hardening film through
solvent evaporation. It seals flanges, fittings, connections and flexible assemblies against
leakage. It increases the reliability of gasket seals.
DIRECTIONS FOR USE
1. Remove all previous material from mating surfaces.
2. For best results, clean and dry all surfaces with a residue-free solvent
3. Remove cap, puncture tube or cartridge seal and attach extension nozzle (if provided).
4. When used as a gasket dressing, spread product with a spatula to a uniform film on one side of gasket
and then position it on the assembly. Coat the second side of gasket and re-assemble. Slower drying
formula increases work time.
5. Assembly is operational after 4 hours, full cure is affected after 24 hours.
For Cleanup
1. The product can be removed from metal surfaces with isopropyl alcohol. If the sealant has been dried
for a long time or at high temperatures, cover the sealant with alcohol and allow to soften overnight.
2. Clean hands with hand cleaners.
3.5 Preventative Maintenance schedule:
Weekly:
1. Visually check for oil leaks from sealed surfaces and fittings.
2. Visually check oil level at the sight glass in LRP® unit stand.
3. Perform general clean up of oil, grease, and dirt.
Six Months:
1. Change oil in LRP® unit base for rack and pinions.
a. See section 2.3.7
2. Change oil in Gearbox.
a. See section 2.3.7
3. Visual inspection of pinions, rack, and gears through housing inspection covers. Check for
excessive wear on gear teeth.
4. Check the brake bolt torque as described in section 2.3.4 and 3.2.
a. During the brake inspection. Remove any debris from the brake. Look for worn,
broken or missing part.
5. Check and verify lubrication oil is be pumped. This will need to be checked as the unit is
running. See Section 2.3.7.
Yearly:
1. Remove/inspect/re-install the cam follower blocks one at a time to inspect the cam
followers. There are 4 block locations (16 cam followers total). Replace any faulty cam
followers that have noticeable radial play and/or a rough feel when rotated or manipulated
by hand while inspecting.
a. Reseal the mating surfaces when reassembling the blocks. See section 3.4
3.6 Spare / replacement parts:

- A mechanical parts list was supplied with the LRP® unit please refer to it for and spare or
replacement parts.
- When inquiring about spare parts please have the model and serial number of the LRP® unit.
These can be found on the white machine tag at the base of the LRP® unit.

Manual Unidades LRP

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LRP® - Linear Rod Pump – Mechanical Manual

Linear Rod Pump Systems

MECHANICAL INSTALLATION AND MAINTENANCE MANUAL

TECHNICAL SPECS: ....................................................................................................................... 3

Gear ratio: __________________________________

Rated Stroke: (inches) 86 100 120

Model number example:

L=LRP RATIO: STROKE: REVISION

Rod rotator option:

1. It is the responsibility of the owner/operator of this equipment to ensure that it is correctly

Before cleaning, inspecting, repairing or performing any maintenance to the equipment,

Equipment Control Precautions

Safe Service Practices

1 About this Manual

1.2.1 What’s Covered

1.2.2 What’s Not Covered

1.3 Intended Audience

Read all manuals first

1.4 Intended Application

2.2 Installation Guidelines

 National Fire Protection Association

NFPA (National Fire Protection Association)

2.2.1 Long Term Storage

2.2.2 Site Planning

• Important: Ensure the stand is concentric and perpendicular to the

2.3.1 Electrical Connections

2.3.2 Retracted Unit Height:

2.3.3 Proximity switch installation prior to start-up:

With the rack in the lowered or

½” deep pocket at both ends of

2.3.4 Installation hoisting procedure:

Remove cross Integral hoisting eyes (2)

2.3.6 Installing the LRP® unit on the Well Head.

Central tube of LRP®

2.3.6.1 Installing with polished rod in LRP® unit.

2.3.6.2 Install over the polished rod.

Top plate is chamfered on the inside

2.3.7 Fill the unit with oil.

2.3.7.1 Base fill port.

Oil fill port for

Oil full sight

Check for oil flow at this fitting. The oil is

Prime the pump in this location. Remove the

Sight glass for

Bonfiglioli name on the

Below are the fill ports for the SEW gearboxes.

2.3.8 Optional rod rotator:

Rod clamp sits on top of

Fill with light oil to bottom

Roller can be used in either of the

Rod rotator sits in the

2.3.9 Top cover installation:

Seal the top cover to

2.3.10 Post Installation Checks:

4. With the unit running, several checks must be made:

Ensure the machine is properly Locked Out prior to any maintenance.

3.1 Oil Change:

3.1.1 Gearbox oil:

Mobilgear 600XP 220 is a mineral based oil.

3.1.2 Rack and Pinion oil

Splitter gear side

Rack and Pinion side

Internal lubrication lines