Pump Operation Manual

OPERATION MANUAL FOR PUMPING UNITS
OPERATION MANUAL
FOR PUMPING UNIT
EG 640-365-168 WFLP
MANUFACTURED FOR LIBERTY LIFT SOLUTIONS LLC
BY
SHANDONG JINZHOU PETROLEUM EQUIPMENT CO.,LTD.

TABLE OF CONTENTS
CHAPTER 1 SAFETY PRECAUTION....................................1

CHAPTER 2 GENERAL INFORMATION...............................2
CHAPTER 3 STRUCTURE INTRODUCTION..................... .5
CHAPTER 4 INSTALLATION...............................................9
CHAPTER 5 OPERATION AND ADJUSTMENT....................17
CHAPTER 6 ADJUSTMENT...............................................20
CHAPTER 7 ADJUSTMENT CALCULATION........................24
CHAPTER 8 LUBRICATION INSTRUCTIONS.......................31
CHAPTER 9 MAINTENANCE............................................34
CHAPTER 10 QUALITY WARRANTY...................................37
CHAPTER 11 PARTS LISTS.................................................38
CHAPTER 1 SAFETY PRECAUTION

Read and understand all assembly and operating instructions and precautions before
attempting to assemble and operate the pumping unit.
PRACTICE SAFETY FIRST

Avoid the possibility of fire when working in the vicinity of an oil well. Be prepared for an
emergency, fire or mechanical failure, in the event that an accident does happen.
The pumping units consist of large and heavy rotating parts. When working around these
machines, it is essential that all personnel involved with the installation, assembly, operation
and maintenance of the pumping units use extreme care and good safety practices at all time.
Failure to use extreme care when working with them can cause severe bodily injury or death.
During assembly of pumping units, a hoisting supervisor should give direction for all hoisting
operations and be located where he is readily visible to hoist /crane operator and can view all of
the hoisting operations. All persons should exercise extreme caution and stay clear of all objects
being hoisted. When working on ladders or work stand, insure adequate footing and holds to
securely assemble the large components.
It should be noted that a pumping unit has components, which can start moving from the
effect of gravity. All personnel should stay clear of the crank and counterweights or other
elements, which may start moving. Times of particular danger from rotating or moving parts
would be during assembly, stroke change, counterbalance change, general maintenance of any
kind. The pumping unit is equipped with a braking system, but the operator should also devise
safety stops from heavy timbers or metal tubing/channels that can be placed under or against
the crank. When the long end of the crank arm is straight down, no rotation will start when the
power source is disengaged, provided the carrier bar has not yet been attached to the polished
rod or the well is clamped off.
Be aware of all power line positions prior to beginning installation or maintenance on or

around the pumping unit. You operation must be organized to avoid all contact with power lines.
Failure to heed this warning could result in severe bodily injury or death to personnel.
All electrical labor must be performed by a qualified electrician, especially on pumping units
that utilize electric motors, or other related electrical devices. The electrical components should
be regularly inspected and maintained in a safe operating condition by a qualified electrician.
Do not operate the pumping unit unless all safety shields and crank guard are securely
fastened in place.
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CHAPTER 2 GENERAL INFORMATION

INTRODUCTION
The purpose of this manual is to provide instruction on installation, operation and
maintenance of a pumping unit. It will provide the means for a safe and efficient installation and
operation. Due to the size of the pumping unit and its components, safety must be stressed
during assembly, at start up and any time that maintenance is performed. Before assembly,
operation or maintenance, review the Safety Precautions section.
The date presented in this manual was current at the time of printing. The photos and
illustrations used in this manual may not look exactly like your pumping units but are
representative and specify the correct parts and instructions required to properly assemble,
maintain and operate your particular pumping units. Improvement and parts change about the
product will not be informed, owner/operator should take the material object as the standard.
WARNING: some pictures in this manual show the pumping units with safety shields
removed for assembly or for a better view of the subject. The pumping unit should
never be operated with any of the safety shields removed.
All the models below are conventional beam pumping unit with crank balanced. The power
configurations depend on requirements of the customer either the electromotor or natural gas
combustion engine.
EXPLANATION OF PUMPING UNIT DESIGNATIONS

The pumping unit, Model 640-365-168 designation numbers is defined as follows:
640 —— 640,000 inch-pounds peak torque rating
365 —— 36,500 pounds of walking beam capacity
168 ——168 inch maximum stroke
PUMPING UNIT DIRECTION
Pumping unit direction: Viewed from the side of pumping unit, the side of the horse-head is
the front of the pumping unit; the motor side is rear; Standing in front of the pumping unit and
facing to the unit, the side on the right hand is the right side, on the left is left.
BOLT TIGHTENING TORQUE VALUES

All bolts used on the pumping unit are important. The surfaces under the bolt head and nut
and the contacting surfaces must be flat, clean, and free of burrs so that the bolted members
join in a "metal to metal" contact. Bolts that are properly tightened according to the manual will
retain their grip under normal operating conditions. Improperly tightened bolts will break in
fatigue and may cause serious failures and injury to personnel.
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THE FOLLOWING TABLE GIVES RECOMMENDED TIGHTENING TORQUES.
TABLE 1. RECOMMENDED TORQUE VALUES

American standard bolt tightening torque table (English)
GRADE 2 GRADE 5 GRADE 8
Bolt
（SAE2）（SAE5）（SAE8）
No No No
Grease Grease Grease
Grease Grease Grease
Specification
ft.lb ft.lb ft.lb ft.lb ft.lb ft.lb
1/4-20 6 4 9 7 13 10
7/16-14 32 24 52 39 73 55
1/2-13 49 37 78 59 111 84
5/8-11 96 73 156 117 220 166
3/4-10 170 128 274 206 388 292
7/8-9 172 129 440 331 622 467
1-8 258 194 659 495 932 700
1 1/8-7 366 275 824 619 1322 994
1 1/4-7 513 384 1154 864 1852 1387
1 3/8-6 675 506 1519 1139 2437 1829
1 1/2-6 891 667 2004 1500 3217 2407
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TABLE 2 MAIN SPECIFICATIONS
Model EG 640-365-168
Load Rating 36,500 lbs
Stroke length 168/139/112 in/in/in
Max stroke frequency recommended 10.7 SPM
Basic
Rated torque 640,000 in-lbs
Parameter
Balanced type Crank balanced
Crank direction Clockwise and Counterclockwise
Rated torque 640,000 in-lbs
Gear type Divided helical, hobbed, Involute gear reducer
Gear Gear ratio 29.489
Reducer
Center range 45.033 in
AGMA EP5 for temperatures down to 0 °F
Gear Lubricant
AGMA EP4 for temperatures down to -30 °F
Weight of counterweight 4×5067 lbs
Balance Weight of crank 2×4906 lbs

Assembly Radius of crank 49.5 in 42 in 34.5 in
Stroke length relevant to crank radius 168 in 139 in 112 in
Wire Line Type 1 1/4” dia 6×25F-IWRC-EEIP
Structure Unbalance -514 lbs
Overall Dimensions Length ×Width ×Height 537.8x105.3x395.8 in x in x in
Total Weight 73400 lbs
Minimum hook height 33 ft
Weight of reducer, crank arms and wrist pins 24257 lbs
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CHAPTER 3 STRUCTURE INTRODUCTION

1. Structure
This product structure and main parts please see figure 1.
FIG.1 PUMPING UNIT STRUCTURE
1. Horse head 2. Walking Beam 3. Polished Rod Hanger
4. Saddle Bearing Assembly 5. Samson Post 6. Equalizer Bearing Assembly
7. Equalizer Beam 8. Pitman 9. Wrist Pin Assembly
10. Crank 11. Gear Reducer 12. Frame & Sub-base & Extension
13. Brake Assembly 14. Crank Guard 15. Belt Guard
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2. Main Parts
1) Horsehead
Horsehead is welded with steel plate. Wire line is hung in the horse-head rope support. The
horsehead connect the walking beam with one pin.
2) Walking Beam
Walking beam is made up of H-rolled steel (or steel plate welded). It is designed according to
the API APEC 11E and has sufficient strength. The front end of walking beam is connected to
horse-head by horse-head pin. There has been installed cross beam bearing frame at the rear
end. Whole walking beam is fixed on support bearing seat.
3) Polished Rod Hanger

For the wire line，The wire line is composed of multiplayer, no torsional steel wire. Its length
and type refer to main specifications table. There are caps at its two ends whose top joins with
the rope supporter on the horse head top and bottom joins with carrier bar.
The wire line is designed according to the API SPEC 11E.
WARING! Check wire line periodically. There should be no breakpoint and looseness.
For the Carrier Bar，Carrier bar is used to connect polished rod and wire line, high
strength and stability.
For the Polished rod hanger，it is used to connect polished rod with carrier bar tightly.
With 1 1/2″Polished Rod Slip.（According to customer required）
4) Saddle Bearing Assembly

Saddle bearing assembly, with two anti-frication bearings, is used to connect walking beam
with Samson post. Before installing, sufficient lubricating grease should be added.
5) Samson Post
Samson post is welded by H-rolled steel. It is fixed on the frame and sub-base by bolts and
has sufficient stability.
6) Equalizer Bearing Assembly

Equalizer bearing assembly, with one anti-frication bearing, is used to connect walking beam
with equalizer beam. Before installing, sufficient lubricating grease should be added.
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7) Equalizer Beam
Equalizer beam is made of steel plate by welding with sufficient strength.
8) Pitman
Pitman is made up of upper connecting rod head, lower connecting rod head and I beam by
welding. Upper connecting rod head has shaft sleeve, which has abrasion resistance to prevent
rustiness with connecting rod. Upper head connect cross beam by connecting rod pin. Lower
head is connected with wrist pin and easy to install and remove.
9) Wrist Pin Assembly

For easy installation, a pair of self-align bearings is applied in wrist pin.
Caution: Before installing, sufficient lubricating grease should be added.
10) Crank Assembly

Crank is made of cast iron. Crank is installed at the two sides of the reducer used wedge to
wedge tightly. Each crank has two differential bolts to lock crank at the reducer low speed shaft.
There are three wrist pin holes in crank. The wrist pin can be installed in different hole to get
corresponding strokes. There are gear rack and crank balancing weight in crank. Adjust
counterweight to get the best balance efficiency.
11) Gear Reducer

Gear reducer is divided-flow type ，herringbone，involute gear reducer, the particular
parameters please refer to main specifications table. Reducer uses extremely pressure gear oil
to lubricate. Gear is based on oil sump immersion method to lubricate. Bearing of the input
shaft is based on gear oil splash to lubricate. Bearings of the middle and the on put shaft are
lubricated by oil wiper.
Oil level indicator has been installed in reducer box to check oil level. Dipstick slot has been
installed on reducer cover to check oil level by dipstick.
Caution: Reducer middle shaft and draft shaft covers have oil slot. When maintaining them,
pay attention to its position and there should be no oil way plug, otherwise, bearing will lack
lubricate oil to cause destruction of middle shaft bearings and output shaft bearings.
WARING! Check brake wheel and reducer drive sheave periodically. There should be
no flabby instance occurred.
12) Frame
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Frame is used to support and fix pumping unit, with sufficient stability. The base is not only
applicable to motor but also to gas engine.
Note: Base must be sit on concrete foundation, which should steadily sit compaction ground
and pumping unit base has no vibration, otherwise, it might fracture.
Warning: The soil under concrete foundation must be compacted. Concrete

foundation must fill with solid and align. When operating pumping unit, concrete
foundation should not vibrate and pumping unit should not vibrate. If concrete foundation is
not steady, pumping unit base may fracture or bring some other failures.
13) Brake Assembly

The brake assembly is composed of a set of rigid parts (or soft brake axis). One end of the
assembly connect with brake lever, the other is fit on brake drum. Because of considerable unit
inertia, braking do should be smooth.
Do not jam the brake!
14) Crank Guards

Warning: Do not operate pumping units unless crank guards and other needed
guards are in place. Rotating parts are dangerous to personnel.
The mesh crank guard is sold as an optional piece of equipment to provide safety for
people or animals, which may be required to be in the vicinity of the operating pumping unit.
The guard would normally be considered adequate guarding for people familiar with the
operation of a pumping unit and accustomed to working around it, as well as smaller animals
which might be able to move through when guard rails described above.
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CHAPTER 4 INSTALLATION
Pumping Unit Installing Orientation

Consider the local main wind direction to avoid the leaking gas and oil liquid blowing to the
pumping unit and motor. The well field conditions must also be considered in order to secure
enough space for oil service easily.
Notice: Before installation, consider stroke length, carrier bar lower dead point height and
wellhead height enough to make appropriate height concrete foundation. We suggest that
concrete foundation height should be in the range from 15.75in—23.622in.
1. FOUNDATION
The foundation uses 400# concrete. Prefabricate 200# concrete. Customer can make integral
foundation or segment. Please see Figure 2.
The foundation should be positioned in accordance with a foundation plan only. A copy of
this plan is shipped with the unit. This foundation plan shows the hold down bolt location in
relation to the wellhead, bolt and anchor nut sizes and number. No attempt is made on the
foundation plan to prescribe the shape, depth nor characteristics of the foundation. The
contractor must supply this information based on their knowledge of and experience with the
soil conditions as they exist at the well site and assume full responsibility for the quality of the
foundation.
Foundation tie down bolts must be hammered tightly after concrete has been set up and
pumping unit base alignment is complete. The foundation plan is shown as Figure 2
The bottom of concrete foundation must be filled with gravel. Unsteady foundation may
cause the broken of the unit's base easily. Levelness of the concrete foundation upper surface
should be checked from front back＆right left directions and draw out the foundation's central
line. The central line shall point straightly to the wellhead center. Their lateral differential is not
over 10mm (0.4in)
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Fig.2 Foundation of EG640-365-168 WFLP

10
Whether integral foundation or segment foundation, pumping unit anchor bolts must be taken
anticorrosive step, first filled with soil into anchor bolt bore, then seal with asphalt.
2. SETTING AND ALIGNING THE BASE

Review the Safety Precaution of this manual prior to beginning erection of the pumping unit.
Step 1: Adjust substructure position. The dimension differential from
vertical projection of supporter bottom plate on the support top plate
center (mark hole on the supporter body) to well head is ±0.1in.
Step 2: Adjust substructure body levelness. Vertical levelness

differential is not over 0.03in/ft. and front is high, back is low.
Horizontal levelness differential in cross direction is not over 0.024in/ft. Upper flat horizontal
levelness differential is not over 0.018in/ft.
Step 3: Base substructure on concrete. Central line mark hole on the substructure body should be
adjusted carefully to make the line center direct the wellhead. There differential is not over 0.04in
and assemble differential is not over 0.12in.
The base and concrete foundation horizontal can be adjusted by adding sloping iron or backing
plates. The number of backing plates in each group shall not exceed 3 pieces; its total thickness is
less than 10mm and the contact shall be secured homogeneous.
After adjustment, fix substructure body on concrete foundation by anchor screw.
3. GEAR REDUCER INSTALLATION

WARING! The reducer with cranks is an assembly that comprises heavy rotating
components. All personnel must exercise extreme caution when lifting this assembly
to ensure that the cranks are locked to prevent rotation.
Step 1: To install the reducer on its sub-base, attach slings or chains
to the reducer and both cranks for proper stabilization. Mark the
centerline on top of the sub-base and bottom of gear reducer and
utilize this line for initial alignment. Place the reducer on the sub-base
and install the bolting, leave the bolts loose for alignment shifting.
Step 2: The cranks should now be rotated to a safe position; the long
end down. Remove the chains from the reducer but not the cranks.
Disengage the brake lock-out and clear the crank sweep area. Slowly
11
release the brake lever to allow the cranks to rotate to bottom dead center. The chains may now
be removed from the cranks
Step 3: Tighten all bolting on gear reducer and bolting on sub-base.
4. BRAKE RELEASE AND ADJUSTMENT PROCEDURE
Step 1: Release the brake by loosening the brake lockout nut.
Step 2: To adjust the brake pads, continue loosening the brake

adjustment nut until the proper clearance is achieved between the
brake lining and the brake hub.
Step 3: Tighten the nuts and adjustment bolts to maintain proper

adjustment.
5. BRAKE LINKAGE ASSEMBLY PROCEDURE
Step 1: Connect one end of the vertical rod to the bell crank and
secure it with the adjusting rod nut.
Step 2: Loosen the lock nuts and adjust the vertical brake rod length
so that the bell crank is horizontal when the brake pads contact the
hub.
Step 3: Connect the upper end of the vertical rod to the cam.
Step 4: Connect one end of the horizontal brake rod to the yoke at
the brake handle assembly.
Step 5: Adjust the length of the horizontal rod between the bell crank and the brake handle so
that the cam is horizontal when the brake handle is in the forward position.
Step 6: Connect the other end of the horizontal rod to the bell crank.
Step 7: Tighten all yoke nuts to maintain adjustments.

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6. INSTALLATION OF COUNTERWEIGHTS ON CRANKS
Step 1: Set the position of the counter weight according to the field
situation.
Step 2: Insert a chain or cable through the holes in the

counterweight.
Step 3: Install the "T" bolts in the slot of the crank.
Step 4: Set the counterweight on the bolts.
Step 5: Install a flat washer, a standard nut, and jam nut on each of
the counterweight bolts and tighten securely.
Step 6: Repeat the installation procedure for each of the counterweights to be installed.
7. SAMSON POST ASSEMBLY
Step 1: Assemble the support leg to the Samson post, using the bolts furnished. Do not tighten
the bolts securely at this time.
Step 2: Lift and mount the samson post on the base. (Before lifting,
the lubrication line has been attached to the Samson post).
Step 3: Use a bolt or wrench to align the holes of the Samson post
with the base.
Step 4: Insert and tighten all bolts that secure the Samson post
assembly to the unit base.
Step 5: Tighten all bolts at the top of the rear support beam using an alternating sequence from
one side of the unit to the other. This will avoid inducing uneven stresses in the flanges.
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8. ASSEMBLY AND INSTALLATION OF LADDER TO STRUCTURE
Step 1: Assemble the brackets to the ladder, leaving the bolts only hand tightened. On units with
two supports, the longer will be used at the top of the ladder, the shorter one is used at the
bottom of the ladder.
CAUTION: All bolts should be installed so that the bolt heads are on the
inside of the ladder.
Step 2: Position the ladder safety ring on the outside of the ladder rails
at the top of the ladder and screw down securely.
Step 3: Position the ladder against the Samson post and tighten all bolts securely.
9. INSTALLATION OF PITMAN ARMS TO EQUALIZER
Step 1: Position the equalizer on the ground so that the equalizer bearing housing bolt holes are
on top of the beam.
Step 2: Select the pitman arm which has the lubrication line attached
to it. Note the position of the lubrication line on the equalizer. The
two should be assembled so that the lubrication lines are on the same
side.
Step 3: Equalizer holes should be cleaned thoroughly prior to inserting upper pitman pins in
housings. Pitman pins should be covered with a rust preventative coating.
Step 4: Mount the pitman to the equalizer beam and insert the upper pitman pin in the housing
holes. Install the bolts and tighten them.
Step 5: Connect the lubrication line from the pitman arm to the equalizer.
Step 6: Attach and assemble the other pitman member according to the same procedure.
Step 7: After installation，add grease to Equalizer holes.

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10. INSTALLATION OF WALKING BEAM TO EQUALIZER
Step 1: Loosen the bolts on the two-equalizer clamp and install on the
equalizer bearing assembly pin (already attached to walking beam).
Step 2: Position the flanges on the equalizer assembly to align with

those on the equalizer beam.
Step 3: Install bolting and nuts and tighten with hammer wrenches.
11. INSTALLATION AND ALIGNMENT OF SADDLE BEARING TO WALKING BEAM
Step 1: Position saddle bearing on the ground with larger mounting

flange facing upwards.
Step 2: Lift the walking beam and position the center of the beam
on the saddle bearing. Insert the bolts and loosely tighten.
12. INSTALLATION OF WALKING BEAM ASSEMBLY TO STRUCTURE
Step 1: Attach lifting ropes near each end of the walking beam
assembly to ensure a level lift.
Step 2: Position the saddle bearing housing on the top of the Samson
post. Insert the bolts and hand tighten
Step 3: Attach the pitman arms to the wrist pin assemblies and
securely tighten all bolts.
Step 4: Attach one of flexible hoses on the Samson post to the center
bearing, the other flexible hose to the walking beam.
13. INSTALLATION OF WIRELINE ASSEMBLY TO HORSEHEAD
Step 1: Place the wire line assembly in position on the horse head.
Step 2: Position the carrier bar so that it is relatively straight with the
15
open end facing the polish rod.

Step 3: Install the bolts in horse head to secure the wire line assembly.
Step 4: Install the horse head adjusting bolts.
14. INSTALLATION OF HORSEHEAD TO WALKING BEAM
Step 1: Lift the horse head into position and place the roll bar behind
the flange on the walking beam.
Step 2: Install the safety flag through the horse head and angle slot on
the walking beam and tighten adjusting bolts
15. INSTALLATION OF PRIME MOVER
Position the slide rails on the slots near the end, which is toward the reducer so that the belts
can more easily be installed after positioning the prime mover. Face the slide rail to match the
mounting holes on the prime mover. Similarly install and space the bolts in the slots on the slide
rails. Carefully lower the prime mover onto the slide rails. Install the nuts without tightening until
the belt alignment is complete,
16. V-BELT INSTALLATION AND ALIGNMENT
Install a matched set of belts, always using the inside grooves if

either sheave has an excess number of grooves. Utilize a string to
align the inside faces of the sheaves (see photo). Shift the prime
mover as required and then tighten the bolts that attach the prime mover to the slide rails.
Tighten the belts by using the adjustment screws. All new belting should be rechecked for
tightness after 24 hours.
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CHAPTER 5 OPERATION AND ADJUSTMENT
1) CHECK BEFORE INITIAL OPERATION

After erection of the unit is complete, the following checks must be carried out:
Check if the foundation is steady and solid.
Check and fasten all anchor bolts.
Check all the lubricating points to ensure all of them have been lubricated very well.
Check all the connection parts to ensure all of them have been connected well.
Check driving belt, the tension should be proper.
Check brake, it should be flexible and reliable.
Check if the installation of electrical circuits and appliances abide by technical and safety
requirements.
Check the unit if there are external substances hindering the running of the unit.
Check ladder to ensure it is fixed firmly.
Pay special attention to that if the lock dog of the unit's brake safety system has been lifted and
the brake has been loosening.
2) INITIAL OPERATION
Startup motor; five minutes later brake the unit and check
If the wire line is tortuous in running, adjust it.
Carrier bar should be horizontal and have no incline and no bending, otherwise, adjust it.
Tension of driving belt should be proper, not too tense or any sliding, otherwise, adjust it.
Horse-head should not have any vibration in running.
Samson Post shouldn't have any oscillation in operation.
The reducer shouldn't have any oscillation in operation.
The prime mover shouldn't have any abnormal sound in operation.
Brake should be flexible and reliable.
Check all the connection bolts ensure all of them are fixed firmly.
After you have done all the above, please dislodge the safety measures and restart the prime
mover.
3) AFTER 24 HRS. OPERATION

Listen for unusual noises. If any occur, locate cause and take necessary corrective action.
Apply brake slowly several times to be sure it is functioning properly before using it position
cranks.
17
DO NOT JAM BRAKE. Always apply brake lever slowly and firmly.
Caution: Abrupt braking may shear gear teeth in reducer causing excessive down time.
Stop prime mover and slowly apply brake to stop pumping unit with cranks horizontal toward
well.
When brake holds cranks without slippage, release brake lever solely and allow cranks to
re-position themselves in the DOWN position .If electric motor is used, ti be sure master switch is
locked out. Chain or block cranks to prevent their movement. Clamp of well at stuffing box.
Danger! Do not work on or near cranks or counterweights until they are chained or blocked to
prevent their movement. Serious injury or death could occur if you do so.
Check all bolts including hold down clamp bolts for tightness.
Re-tighten prime mover hold down bolts.
Re-check alignment to make sure that wire line tracks horse head properly.
Remove chains or blocking from cranks, remove wellhead clamp at stuffing box, release break and
start prime mover to resume pumping.
4) AFTER FIRST TWO WEEKS OPERATION

Listen for unusual noises. If any occur, locate cause and take necessary corrective action.
Apply brake lever slowly several times to be sure it is functioning properly before using it
position cranks.
DO NOT JAM BRAKE. Always apply brake lever slowly and firmly.
Caution: Abrupt braking may shear gear teeth in reducer causing excessive down time.
Stop prime mover and slowly apply brake to stop pumping unit with cranks horizontal toward
well.
When brake holds cranks without slippage, release brake lever solely and allow cranks to
re-position themselves in the DOWN position .If prime mover is electric, be sure master switch is
locked out. Chain or block cranks to prevent their movement. Clamp of well at stuffing box.
WARNING! Do not work on or near cranks or counterweights until they are chained or
blocked to prevent their movement. Serious injury or death could occur if you do so.
Check reducer oil level. If the level is low, remove the inspection cover and add oil to the
proper level.
Visually inspect the structural bearings for oil seal leaks. This would include the wrist Pin ,
equalizer and center bearing assemblies. Grease fittings are located at ground level, and if
needed, the grease should be pumped in slowly to avoid pushing out the oil seals.
Check all bolts including hold down clamp bolts for tightness.
Re-tighten prime mover hold down bolts.
Remove chains or blocking from cranks, remove wellhead clamp at stuffing box, release break
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and start prime mover to resume pumping.
5) AFTER SIX MONTHS AND EACH SIX MONTHS THEREAFTER

Before do the maintenance for the pumping unit, you must obey all the safety specifications
mentioned above.
It is recommended that an oil sample be taken every six months to determine condition of the
oil. Collect a typical sample of the reducer oil in a transparent receptacle. A visual inspection will
expose possible dirt, sludge, water emulsion, or other forms of contamination. You may also
desire to determine that you have any of the following conditions in the lubricant, check with a
qualified vendor regarding replacement:
1) An acid or singed odor indicates oxidation of the oil to the degree that it should be replaced.
2) If sludge is observed in the used sample, the oil should be replaced or filtered to remove the
sludge. This condition is prevalent if the lubricant has not been changed for a long period of time.
3) If water exists in the used sample, the water should be completely drained from the reducer.
Subsequent bubbling will occur with as little as 0.1% of water present in the oil. If there is greater
than 0.2% water by volume, an oil change is recommended.
Visually inspect the wire line for wire fraying .A rusty wire line should be cleaned and coated
with a wire line lubricant as specified in the manual.
Belt alignment and tension should be checked and adjusted to prolong belt life. Under normal
utilization belts will stretch and wear. It is recommended that new belts be retightened after the
first 24 hours of operation.
Check all bolts. Tightening torques refer to the table 1.
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CHAPTER 6 ADJUSTMENT
1. COUNTERBALANCE ADJUSTMENT
Efficient operation, torque loading, and maximum life of a pumping unit are all dependent on
the proper counterbalance. Counterbalance requirements can be determined very accurately or
estimated by various methods.
1) Polished rod dynamometer:
A dynamometer card analysis is the most accurate method for determining loading and
counterbalance. This involves using a dynamometer to record the well load through a stroke
cycle and then using torque factors to determine the reducer torque and counterbalance
required for balanced conditions.
2) Ammeter:
A clip on ammeter may be used to compare the upstroke and down stroke current on
electrically powered units. When the counterbalance is adjusted so that the current peaks are
equal, the unit will be roughly in balance.
3) Vacuum Gauge:
A vacuum gauge may be used to compare torque peaks on engine driven units much like the
ammeter is used on electrically driven units. Vacuum pressure decreases as engine output
increases.
4) Sound of the Prime Mover:
An approximate estimation of balance can be made by listening to the characteristic sound of
the prime mover as it drives the unit. Some speed change will occur as the peak loads are
approached-, speed changes will cause the sound of the prime mover to vary.
5) Belt Tension:
Belt tension and subsequent belt stretch increases with load. This causes an proportional
amount of slack in the belts on the side opposite the direction of rotation of the prime mover. A
visual inspection of the belt sag on upstroke or down stroke can be used to estimate
counterbalance.
Counterweight Adjustment
Rotate the unit and apply the brake so that the crank is slightly downhill in the direction that
the weights are to be moved. Set the brake, engage the brake lockout bolt or pawl, and secure
the cranks against rotation. Loosen the counterweight bolts just enough to allow the weights to
be moved. Use the pinion adjusting wrench to move the weights to the desired position. It is
important to note that larger weights may have to be moved with the aid of a crane or a pry bar.
The weight on the crank may be moved in a similar manner. After positioning the weights in the
desired location, tighten the counterweight bolts utilizing recommended levels of tightness, and
20
add a second nut for a jam nut.
2. CHANGING STROKE LENGTHS

Locate the cranks at approximately the 2 o'clock position and set the brake. Place a
polished-rod clamp at the stuffing box and tighten according to the clamp manufacturer's
recommendations. Using the prime mover or a crane-lift, relocate the cranks to the 12 o'clock
position and set the brake.
You may now disconnect the carrier bar from the polished rod. Insert a long chain through the
carrier bar and install the gate back into the carrier bar. Hold the end of the chain and pull the
carrier bar away from the polished rod while slowly releasing the brake and letting the cranks
down to the 4 o'clock position.
Always disconnect or lockout the prime mover. Remove the crank guard side panel to gain
access to crank area, secure the unit against rotation by the brake locks out bolt or pawl. Place
one 1-1/2 ton come-a-long between the carrier bar and the front cross-member of the base.
Place another between the equalizer and the holes on the front of the sub-base. Tighten both
come-a-longs to restrain possible movement or tilting of the walking beam that will occur once
the wrist Pin s are removed from the cranks.
1）Wrist Pin Removal
Remove the cotter pin and then remove the wrist Pin nut using the box end hammer wrench
(furnished as an option), and a minimum 14 pound sledge hammer with a full length handle.
Drive out the wrist Pin using a drive nut and tools above. The drive nut (furnished as an option)
is screwed on until it bottoms on the end of the pin. Hammer against the head of the drive nut
until the pin is loose. If a drive nut is not available, it is recommended that the hammer hit as
squarely on the end of the pin as possible to prevent surface damage. Once the pin becomes
loose, do not remove it from the hole. Remove the drive nut and install the original nut three or
four threads deep. This procedure should also be used on the opposite wrist Pin .
Check the wrist Pin clearance in the hole and adjust come-a-longs accordingly so that when the
pins are removed they will not fall nor pull up in a sudden motion. Remove the nuts and pull the
wrist Pin s out of the crank holes. The pitman side members will support the wrist Pin bearing
assemblies until the pin is installed into another hole. It is recommended that rust preventive be
applied to the wrist Pin bore after the pin is removed.
2）Wrist Pin Installation
Step 1: Use a safe solvent to clean the wrist Pin, wrist Pin hole, and
the surface of the crank that the nut will seat against. Remove all
paint, burrs, and other foreign matter from these areas. Always
21
inspect the wrist Pin and hole surfaces for rust or wear, as these conditions may indicate that
the wrist Pin was loose. Use a spot bluing to check the contact between the pins and the new
holes.
Step 2: Adjust come-a-longs to line up the wrist Pin s with
the proper holes for the stoke length desired. Apply a light coat of oil
on the tapered pin, threads, and wrist Pin hole. All excess oil should
be wiped off with a clean cloth prior to inserting the wrist Pin high
alloy bushing into the crank hole.
Step 3: Install the wrist Pin assembly.
Step 4: Using the box end hammer wrench, tighten the wrist Pin nut.
This will establish the metal to metal position for the final tightening
procedure.
Step 5: Using a sledge hammer on the wrench, turn the nut

two cotter pin notches past the hole in the pin and line up the hole in
the pin with the third cotter pin notch. Install the cotter pin. Never
back the nut off to insert the cotter pin. If you have turned the nut
too far, remove the wrist Pin and repeat all of the installation procedures.
3) Returning the Unit to Operation

With the brake engaged, remove the come-a-longs, unchain the drum and disengage the lock
out bolt or pawl.
Reinstall the crank guard panels.
Hold the carrier bar away from the polished rod with the chain and slowly release the brake to
let the cranks go to the bottom. Engage the prime mover (or crane) to slowly reposition the
cranks at 12 o'clock while holding the carrier bar away from the polished rod. Remove the chain
from the carrier bar and attach the carrier bar to the polished rod-, please note that the bottom
hole pump spacing will need to be checked and the polished rod clamp may have to be
repositioned to accommodate the new stroke length.
Slowly release the brake to transfer the well load back to the carrier bar. Make certain that the
load is not on the polished rod clamp at the stuffing box. If necessary, use the prime mover to lift
the load. Remove the polished rod clamp at the stuffing box that was used to clamp off the well
load.It is important to note that after a stroke length change, the counterbalance should be
checked and the weights repositioned for the proper balance.
22
CHAPTER 7 ADJUSTMENT CALCULATION

Pumping unit equilibrium directly influences reducer and motor load, life and whole machine
running stability. So before erecting the pumping unit, preliminary equilibrium should be
calculated and adjusted according to the situation of the oil well and the pumping unit, in order
to avoid the serious non-balance when the pumping unit working. After pumping unit put into
production, adjust equilibrium according to crankshaft actual torque to assure pumping unit
operate in the best condition.
1.Preliminary Calculation of The Pumping Unit
Before erecting the pumping unit, preliminary equilibrium should be calculated and adjusted
according to the situation of the oil well and the pumping unit, in order to avoid the serious
non-balance when the pumping unit working.
1) Balance Torque Required
Calculating according to one of the following formula:
M BT ＝0.470 x （ PR - G + PO /2）× S ………①
TF75 + (Pmax + Pmin )

M BT = ………②
2 sin 75
| MUmax | + | M Dmin |
M BT = ………③
2 sin 75
Note:
MBT balance torque (N.m)
PR weight of the sucker rod inside oil (N)
PO oil weight on the sectional area of the oil pump plunger above the dynamic liquid level
(N)
G weight of the construction non-balance (N)
S length of stroke of the pumping unit (m)
TF 75° torque factor at 75°(m)
Pmax the maximum load of the landing top (N)
Pmin the minimum load of the landing top (N)
MUmax the maximum moment of torsion between the load of the upstroke landing top and the
crank axis (Nm)
MDmin the minimum monument of torsion between the load of the down-stroke landing top
and the crank axis (Nm)
Besides：
PR =q' L= PR(1-r/7.85)=qL(1-r/7.85) ④
23
P'O = r×L'×F×g×1000 ⑤
MUmax =(Pmax-G)× TF 75° ⑥
MDmin =(Pmin-G)× TF 285° ⑦
Note:
PR weight of the sucker rod in air (N)
q' weight of the sucker rod per meter in the oil (N/m)
L depth of the pump setting (m)
L' depth of the dynamic liquid-level (m)
r density of oil-liquid (kg/m3)
F section area of the pump plunger (m2)
g acceleration of gravity (N)
TF 285°torque factor at 285°(m)
Pmax and Pmin can be read from relevant documents, or calculated according to the experience
formula or the following formula.
Pmax ＝ PO ＋ PR ×（1＋ S × N 2 ／1790 ） ⑧
Pmin ＝ PR ×（1－ S × N 2 ／1790） ⑨

or
Pmax ＝（ PO ＋ PR ）×（1＋a 上/g） ⑩
Pmin ＝ PR ×（1＋7.85/(7.85-r) ×a 上 /g） ⑾
Note：
N Stroke frequency of the pumping unit (L/min)
AU The maximum acceleration of the landing top upstroke
Calculating the mounting place of the counterweight
a . According to The Following Formula ZX
Z X ＝（ M BT － M C ）／ QCW ⑿
Note
ZX Distance between the assembly gravity center of crank counterweight and the center of
the crank axis bore (refer to figure4) (m)
MC Counterbalance moment between the double crank body (Nm)
QCW Total weight of the counterweights (Ｎ)
and
QCW ＝ WCW × n p ....…………… ⒀
24
Note：
WCW Weight of single counterweights Ｎ
np The amount of the counterweight in general, 4 or 2
b. According to Balance Weight Position and Distance Mark on Crank

Gravity center of balance weight refer to figure 4.
Gravity center of balance weight is situated at the cross of the two vertical connecting line
between three hoisting bores and one safety locking segment bore. When installing, gravity
center is pointed by safety locking segment bore.
Balance weight assembly bar center position: one balance weight position is its gravity center;
two counterweights position is the connecting line center of the counterweights gravity center (or
connecting line center of the two balance weight safety locking segment bore). Refer to figure 4.
At the crank, cast scale marks has “0、5、10、15…75、80、85” to show that the distance between
two adjacent scale marks is 1in
Note: Some factory use “△” to point scale marks to show balance weight position. Balance
weight position is according to factory explanation.
FIG. 4 GRAVITY CENTER OF THE COUNTERWEIGHT

2. Examination of the Pumping Unit Equilibrium
After beginning to work, the pumping unit must be confirmed non-overload and in balance.
Examination of the pumping unit balance, power balanced method, torque moment balanced
method or current balanced method can be all used.
For example, the current balanced method is that after the pumping unit balance have been
adjusted, the maximum different current value between the upstroke motor and the down-stroke
motor of the pumping unit should be confirmed to be no more than 15% of the maximum
current.
That is : current balanced rate  ≥85％：
25
| IU max－I D max |
 = (1 − )  100%  85% ⒁
I max
Note：
 Current balanced rate of the motor
IUmax The maximum current of the upstroke motor (A)
I Dmax The maximum current of the downstroke motor (A)
I max The maximum current of the motor when the pumping unit rotate on circle (Ａ)
3. Calculating on Exactly Adjusting Balance in Operation
After the pumping unit begins to work, the balance should be exactly adjusted within 48 hours.
When the work factor of the pumping unit adjusted, the balance should be exactly adjusted at
once.
According to the pumping unit working condition, oil well pump and pumping rod, the balance
should be adjusted in order that the pumping unit should work under the best balance condition.
Now we can adjust and calculate according to the following two method:
a. Current Method
M I −I
m ZX =  Umax Dmax ⒂
QCW IU max + I Dmax
Note：
mZX Distance that the assembly gravity center of the crank counterweight should move in
order to reach to the balance (m)
mZX >0, meaning that the assembly gravity center should depart from the crank axis center
to moving outside
mZX <0 meaning that the assembly gravity center should move to the crank axis center
M  calculating according to the following methods：
M  ＝ Mn max ＝30 S ＋0.236 S （ Pmax - Pmin ）.. ⒃
M  ＝ Mn max ＝0.236 S （ Pmax - Pmin ）-100 N 2 ⒄
M  ＝ M X ＝ M C ＋ QCW Z X ＋ G × TF 75° ⒅
Note：
Mn max the maximum net torque of the crank axis
M X effective counterbalance torque (Ｎｍ)
Pmax and Pmin have the same meaning as the above, but Pmax and Pmin should be obtained
from the indicator diagram in the near future.
According to calculated
mZX to adjust balance.
Note: current method has its limits. When pumping unit is imbalance seriously, that is, one of the
IUmax or the IDmax is motor generated feedback current, this formula can’t be used.
26
When IUmax<0, move the balance weight to the crank shaft center closely; When IDmax <0, move
the balance weight to the crank shaft center far away; When IUmax>0 and IDmax >0, according to
current method to calculate accurately.
Judging motor generated feedback current in upward stroke or down stroke has two ways,
One way: if panel box has installed watt-hour meter, see if the watt-hour meter aluminous pan
reverse in upward stroke or down stroke max current. If reverse, there is feedback current.
The second way: when the pumping unit max current in upward stroke or down stroke, hear
motor sound and see motor rotate speed, if the rotate speed has exceeded rated value, there is
feedback current.
b. Torque Method
step 1: calculating on the net torque of the reducer (Mn)
Mw ＝ TF ×（ W － G ） ⒆
Mn ＝ TF ×（ W － G ）－ M × sin ( −  ) ⒇
Note：
Mw torque of the polished rod (Nm)
Mn net torque of the reducer (Nm)
TF torque factor at 
W the load of the landing top, the crank angle 
M the maximum torque of the rotation balance weight Nm
 crank angle of rotation (°)
τ Phase out crank angle
M ＝ M C ＋ QCW Z X (21)
The value of W can be obtained from the indicator diagram in the near future according to the
calculating case of SY5050－84 standard, operation and maintenance of the beam pumping unit
Ａ.3 the factor of the polish rod place required, please refer to the table 4;
 the observer should stand in the left of the pumping unit and face to the pumping unit, and
the well head is in the right of the observer, it is the crank angle per clockwise direction rotation
and started from the 12:00 clock place；
Mn Calculating table is table 3 (that is: calculating table of the net torque of the reducer)
Z X Same to the before-mentioned, that is to say, position of the original balancing weight
installation aggregative barycenter.
Step 2: drawing the curve graph of the net torque after calculated according to the formula 15
and table3, the Mn -  and Mw -  curve graph of the net torque should be drawn.
Step 3 : calculate reducer net torque equilibrium ratiosη,
 BR ≥85%. If the equilibrium ratios cannot reach 85%, pumping unit will be unbalance. Adjust
27
counterweights.
Step 4: calculating the balance torque M BT
| MU max | + | M Dmin |
M BT = ⒄
| sin U | + | sin  D |
Note：
M BT Balance torque Nm
U Crank angle corresponding to MUmax
D Crank angle corresponding to M Dmin
MUmax and M Dmin same to the above mentioned, that is to say, they can be obtained through
calculating indicator diagram of work in the near future and reading max in the upward stroke ,
down stroke on Mw -  curve graph of the net torque
Step 5: calculating the place of the gravity center of the counter weight ( ZX )
Z X Can be calculated according to the formula 12
According to Z X to adjust pumping unit balance.
If the balance rate can’t reach 100%, MUmax may be bigger than M Dmin .
4. Balance Rate of the Reducer Net Torque
Calculating the net torque of the reducer, the balance rate  BR should be more than 85％：
 | M nUmax | − | M n Dmin |
 BR = 1 −   100%
 ⒅
 M nUmax 
Note：
 BR balance rate， BR ≥85％。
MnUmax the maximum moment of torsion of the upstroke reducer (Nm)
MnDmin the minimum monument of torsion of the down-stroke reducer (Nm)
5. Conversion Table
1 ft=12 in=3048 mm 1 lbf=4.44822 N

9
1 in=0.0254 m=25.4 mm 1 ℃= °F+32
5
1 L=1 dm3 1 horse power=735.499 W
1 USgal=3.78543 dm3 1 rad=57.2958°
1 bbl=0.15898806 m3 1 kgf·m=9.80665 N·m
1 lb=0.453592 kg 1 lbf·ft=1.35582 N·m
1 kgf=9.80665 N 1 lbf·ft=0.112985 N·m
28
Table 3 Gear Reducer Net Torque Calculation Table

(Conventional Crank Balanced Unit Only-Clockwise Rotation)
Well no: _______________________________ Company: _____________________________
Unit size: _______________________________Location: _____________________________
θ sinθ W B W-B TF TF (W-B -M（sinθ） Tn

0 0 ) 0
15 0.259 -
30 0.500 -
45 0.707 -
60 0.866 -
75 0.966 -
90 1.000 -
105 0.966 -
120 0.866 -
135 0.707 -
150 0.500 -
165 0.259 -
180 0 0
195 -0.259 ＋
210 -0.500 ＋
225 -0.707 ＋
240 -0.866 ＋
255 -0.966 ＋
270 -1.000 ＋
285 -0.966 ＋
300 -0.866 ＋
315 -0.707 ＋
330 -0.500 ＋
345 -0.259 ＋
Note:
Tn = TF ( PR − B) − MSin
Where:
Tn =Net reducer torque. In .lbs TF =Torque factor at  .in.
 =Position of crank. CB at 90 degrees=___________________
M=maximum moment of counterbalance. In .lbs
M=(CB at 90 degrees-B ( TF at 90 degrees))=_____________________
PR =measured polished rod load at  . lbs.

B=unit structural unbalance. lbs.
29
Table 4 Stroke and Torque Factors
Position Polished Rod Position Torque Factor

of
Crank Length of Stroke, inches Length of Stroke, inches
degrees 168.218 138.961 112.139 168.218 138.961 112.139
0 0.0199 0.0190 0.0182 -24.879 -20.074 -15.783
15 0.0000 0.0000 0.0000 -0.235 0.211 0.369
30 0.0196 0.0200 0.0200 25.321 20.879 16.614
45 0.0774 0.0773 0.0763 48.201 39.373 31.183
60 0.1664 0.1655 0.1630 64.977 53.349 42.504
75 0.2756 0.2747 0.2715 74.073 61.620 49.699
90 0.3934 0.3942 0.3919 76.243 64.453 52.754
105 0.5104 0.5149 0.5151 73.552 63.050 52.285
120 0.6209 0.6300 0.6339 68.067 58.778 49.108
135 0.7216 0.7352 0.7428 61.159 52.633 43.899
150 0.8108 0.8274 0.8376 53.368 45.053 37.019
165 0.8871 0.9040 0.9144 44.429 35.899 28.492
180 0.9480 0.9613 0.9692 33.220 24.526 18.105
195 0.9883 0.9944 0.9973 17.644 10.028 5.651
210 0.9993 0.9969 0.9941 -4.628 -8.001 -8.638
225 0.9708 0.9629 0.9564 -32.613 -28.175 -23.665
240 0.8987 0.8915 0.8845 -59.002 -47.041 -37.560
255 0.7917 0.7886 0.7833 -76.884 -61.239 -48.476
270 0.6641 0.6645 0.6613 -85.629 -69.481 -55.347
285 0.5287 0.5303 0.5282 -87.380 -72.108 -57.937
300 0.3949 0.3959 0.3940 -83.830 -69.858 -56.441
315 0.2702 0.2699 0.2677 -75.733 -63.259 -51.146
330 0.1614 0.1601 0.1579 -63.224 -52.583 -42.335
345 0.0757 0.0742 0.0725 -46.217 -38.034 -30.353
30
CHAPTER 8 LUBRICATION INSTRUCTIONS
All structural bearing assemblies and the gear reducer are designed to provide years’ service,
proper maintenance must be done in accord with lubrication instructions. Many factors govern
the lubrication requirements and maintenance practices, with some factors peculiar only to
certain areas due to type of terrain, prevailing weather conditions and type of production. The
information contained herein may not completely satisfy the necessary requirements of all
pumping units, but if strictly observed as to lubrication points and type of lubricants, unit
downtime will be minimal. Lubricants and time intervals specified are formulated on normal use
of pumping units. If unit is used in extreme environmental conditions, with exceptional heavy
loads or excessive speeds, time intervals between servicing may need to be adjusted. Lubricant
types recommended may also require change to assure continued satisfactory operation.
FIGURE 5 PUMPING UNITS LUBRICATION POSITION
The lubricating requirements:

1) No use of the nonstandard lubricant.
2) No mixing use of different quality's lubricants.
3) In the areas where season temperature is permitted, one brand lubricant can be used in the
31
whole year.
4) If one brand lubricant is not enough, proper brands lubricant shall be chosen and replaced in
Spring and Autumn.
5) Reducer box bottom amass water easily, check it frequently and clear the water to prevent oil
emulsification.
6) Check reducer lubricant periodically to do oil analysis, and then determine exchanging time
according to water cut and impurity ratio in oil.
7) In order to extend using life of reducer, lubricant should be kept clear and away from the
materials such as mud, sands, and iron filings etc.
8) Periodically take samples to check lubricant of reducer; under the following conditions, new oil
shall be changed.
a. There is precipitate sank in the inner-surface of the reducer.
b. Lubricant has emulsified.
c. Lubricant has been polluted by mud, sand and metal particle etc.
Table 5 Pumping Unit Lubricating Table

Lubrication grease (oil) Volume (L) Period
Lubricating
Item Nos Surrounding
position Type Add Change Add Change
temp.
As As
① Carrier bar 1 Steel cable grease
required required
Saddle bearing As Half
② 1 0.3 1
Housing required year
Equalizer Mobilith SHC 220 or As Half
③ 1 0.2 0.8
beam housing equal GREASE required year
Wrist pin As Half
④ 2 0.2 0.5
bearing required year
AGMA
Down 0°F
EP5
Extreme
As As As Half
⑤ Gear reducer 1 AGMA pressure
Down -30°F required required required year
EP4 lubricant
Note: to use grease to lubricate, add lubricating grease every half-year. Avoid adding oil in
winter.
Do re-lubrication as outlined below

1) Before changing the lubricant of the reducer, oil should be discharged and completely flushed
with oil solvent. After flushed, solvent should be discharged, and then flushed again with a little
32
of lubricant. After the flushing oil discharged, new lubricant should be put in at once.
2) After having changed lubricant, don’t run the pumping unit at once, the reducer should work at
least 10 minutes to confirm to cover an oil layer of maintenance in the surface of the reducer
gear.
Add lubricant should pay attention to:

1) Reducer lubricant level should be in upper lever and lower level. Low oil level can lead to gears
and bears bad lubricating. High oil level can lead to reducer oil leak.
2) At the back of reducer, there are two screw holes, which show the upper and lower oil level.
2. Wrist Pin bearing, cross beam bearing and center bearings assemblies are all have been
lubricated at the factory; however it is recommended that all bearing assemblies be rechecked
for proper grease prior to starting unit. Using approved grease; pump the grease into each
bearing assembly until it overflows through the relief fitting located in the bearing cover plate.
Always pump grease in slowly to avoid damage to the oil seals.
3. In addition, hanger screw jack, horse head pin, connection rod pin, brake safety assembly shaft,
brake level pin and so on should be added lubricant to rust prevention or make some of them
rotate agilely.
33
CHAPTER 9 MAINTENANCE
SAFETY STOPS
To prevent accidental injury to nearby persons, install safety devices to prevent
movement of crank or walking beam.
The unit may have some problems during its running; you can locate the cause
and take necessary corrective actions according to the table 6.
TABLE 6 Common Troubles and Trouble Shooting

Failure Cause Correction Action
1. Insufficient bearing capacity of
Drain water; compact soil; install pumping unit
ground, or water soaked under the
again.
concrete foundation.
Packing the concrete foundation, install pumping
2.Unbalanced concrete foundation.
unit again if necessary.
Check main base for rigidity, tighten up the
3. Unbalance main base
pressing bar bolts.
4. Main base break Repair or replace the main base.
5.The horse bolt of subsurface fail to
Tighten up the losing bolt
tighten up
Adjust the pumping unit and make the deviation of
the central line of the main base and the well head
6.Misaligned to well head be less than 3mm(0.12in), The diameter deviation
of the suspending point's projection and the
Pumping unit wellhead diameter is less than Ф18mm(Ф0.7in).
unbalanced Suspending point's load should meet the
7.Polish rod over-loading
vibration requirement of the manual.
8.unsufficient load of the polished Suspending point's load should meet the
rod requirement of the manual.
9.Pumping unit unbalanced Adjust balance
10.Horse head failure Refer to horse head failure section
11.Walking beam failure Refer to walking bean failure section
12.Center bearing seat and center Refer to center bearing seat and center shaft seat
shaft seat failure failure section
13.Samson post failure Refer to Samson post failure section
14.Cross beam failure Refer to cross beam failure section
15.Pitman failure Refer to connection rod failure section
16.Wrist Pin failure Refer to wrist Pin failure section
17.Crank failure Refer to crank failure section
18. Reducer failure Refer to reducer failure section
34
Continued with
Problem Problem Cause Correction Action
1.The steel cable has lacked grease and dried Add lubrication grease
The wire line 2. Parts of the steel cable has been broken Change wire line
abnormally works
3. The wire line cap has been loosen Change wire line
Steel cable twist
Carrier bar not The steel cable is not properly adjusted. Adjust the steel cable
straight.
Connection of 1.The size of polished rod clip and polished rod
Replace the polished rod clip
Carrier bar and un-matching
polished rod loosed 2. Polish rod clip worn. Change the polished rod clip
1. The wire line failure Refer to wire line failure section
2. There is friction between wire line and the said Adjust walking beam or Samson
plate of the horse head post or base
3.The pin of the horse head has been loosen Tighten up it
Horse-head
4.The pin of horse head has been worn Change it
abnormally works,
5.The weld joint of the horse head has been
vibrating and having Repair or change horse head
broken
noise
6.The side plate of the horse head has been
Repair or change horse head
broken
Adjust walking beam or Samson
7.The horse head has sloped
post or base
Adjust the walking beam, and
1.The bolts of center bearing seat are loosen make the deviation of the
suspending point's projection with
2.The bolts of center shaft seat are loosen center line of well head be less
Walking beam was
Ф18mm(0.7in), adjust the place of
displaced or deviated
the walking beam, tighten up the
breadthwise.
bolts of the center bearing seat,
3.The pulling bolts of center shaft seat are loosen tighten up the bolts of the center
shaft seat, tighten up pulling bolts
of center shaft seat
The center bearing 1.The bearing is worn Change the bearing
seat and center
2.Lack of lubrication grease in the bearing of the
shaft seat Add lubrication grease
seat
abnormally works
and having 3.The bolts of the bearing cap are loosen Tighten up the bolts
abnormal noise 4.The gland bolt of the bearing seat loosen Tighten up it
Pitman touch the
crank or Walking beam is deviant installation Adjust walking beam position
counterweight
35
Continued with
Problem Problem Cause Correction Action

Pitman can’t
Pitman pin has been rusted Add lubrication grease
rotate
1.The bolts which connect Samson post and
Tighten up the bolts
main base are loosen
Use the plumb bob to adjust the deviation of
The Samson
the center of the beam and the marking hole
post vibrates
of the main base is less 5mm (0.2in), add the
seriously or 2. The Samson post un-compact
gasket under the connection board of the
leaning,
supporting frame, tighten up the bolt of the
Samson post.
3.Base failure Refer to base failure section
Tail bearing seat 1.The bearing is worn Change the bearing
abnormally 2.Lack of lubrication grease in the bearing of
Add lubrication grease
works and the seat
having
3.The bolts of the bearing cap are loosen Tighten up the bolts
abnormal noise
1.Ential bolts of the crank (the axle of the
Crank runs reducer and the locking bolts for the crank Tighten up the bolts
abnormally, hole) are loosen
loses its speed 2.Wedge key has been broken Change it
or vibrates or 3.The key-slot of the input shaft of the reducer Change the input shaft
jumps has been broken
4.The key-slot of crank broken Change crank
Operate the pumping unit according to
1. Pumping unit is overloaded.
manual.
Operate the pumping unit according to
2.Insufficient load
manual.
Wrist Pin Operate the pumping unit according to
3. Stork frequency is more than usual.
works manual.
abnormally. 4. Pumping unit is unbalanced. Adjust the pumping unit to balance.
5. Connection rod is interfered by wrist Pin . Adjust the position of the pumping unit or
Periodic noise adjust the assemble position between
from wrist Pin . connection rod and wrist Pin . The difference
distance between each connection rod inside
Wrist Pin and crank processed surface must be less
displaced on than 3mm (0.12in).
axial direction. 6. Wrist Pin and wrist Pin hole is not Check the cone surface of wrist Pin and
mated tightly. wrist Pin jacket. If they are worn, change
them.
7. The mated surface between Wrist Pin and Clean the wrist Pin , the wrist Pin cone
wrist Pin hole is not clear. jacket and the wrist Pin hole.
36
CHAPTER 10 QUALITY WARRANTY
1. Content and Validity of Warranty
If pumping unit accident occurs in the period of guarantee, we provide the following to quality:
From pumping unit leave factory 36 months, we warrant that the goods under normal operating
condition will be free from repairing or replacing the defective parts for a period of guarantee.
We are responsible for only to pumping unit and don’t indemnify to other and any bodily injury.
2. Content Out of Warranty
The following situation is out of warranty:

1) Modification without our written agreement.
2) The accident or damage caused by the foundation sinking or improperly cast foundation.
3) Main base fracture caused by the unsteady foundation.
4) The failure, accident or damage caused by breach of the required installing, operating or
maintaining in this manual.
5) The failure, accident or damage caused by breach of operating rule.
6) Lubricant is not the required type.
7) The pumping unit is operated in excess of overloaded condition or under min suspended load
condition.
8) The pumping unit is operated under seriously unbalance conditions.
9) Accident or damage occurred out of our responsibility.
37
CHAPTER 11 PARTS LISTS

1、 Pumping unit
Item Drawing number Parts Qty

LLII640.16.15.01J-00 EG640-365-168 WFLPMC
1 LLII640.16.15.01-01 Horse head 1
2 LLII640.16.15.01-02 Walking beam 1
3 LLII640.16.15.01-03 Polished Rod Hanger 1
4 LLII640.16.15.01-04 Saddle Bearing Assembly 1
5 LLII640.16.15.01-05 Samson post 1
6 LLII640.16.15.01-07 Equalizer Bearing Assembly 1
7 LLII640.16.15.01-0801 Equalizer Beam 1
LLII640.16.15.01-0802 Pitman 1
8
LLII640.16.15.01-0803 Pitman 1
9 LLII640.16.15.01-09 Wrist Pin Assembly 2
10 LLII640.16.15.01-10 Crank Assembly 1
11 LLR640.06-00 Gear Reducer 1
12 LLII640.16.15.01J-11 Frame & Sub-base 1
13 LLII640.16.15.01J-13 Brake Assembly 1
14 LLII640.16.15.01J-15A Crank Guard 1
15 LLII640.16.15.01J-14 Belt Guard 1
38
2、 Saddle bearing assembly
ITEM PART NUMBER DESCRIPTION QTY.
LL04011 SADDLE BEARING ASSEMBLY

1 LL5HN014 NUT, HEX, 1.5-6UNC,GRADE 5 8
2 LL04017 TRUNNION 1
3 LLWFW014 WASHER, FLAT, WIDTH, 1.5 4
4 LL5HB904 BOLT, HEX, 1.5-6UNC×7,GRADE 5 4
5 LL04010 TRUNNION PIN 1
6 LL04012 SHAFT 1
7 LLCPB002 BEARING, F6.5×12 2
8 LLCPGF001 FITTING, GREASE, .13NPT 1610BL 2
9 LL07006 RETAINER RING 2
10 LL04019 PEDESTAL ADAPTOR 2
11 LL04015 TRUNNION CLAMP 2
12 LL8HB609 BOLT, HEX, 1-8UNC×4.5,GRADE 8 4
39
3、 Equalizer bearing assembly
LL07022 EQUALIZER BEARING ASSEMBLY
1 LLCPWHM005 RTNG RING, WHM-1200 2

2 LLCPGF001 FITTING, GREASE .13 NPT 1610BL 1
3 LL07027 RETAINER RING 1
4 LLCPB009 BEARING, GG 6 7/8 1
5 LL07023 SHAFT 1
6 LL07025 HOUSING 1
7 LL07026 BOLT, STUD, 1.5-6UNC×7.3, GRADE 8 8
8 LLCPHWF014 WASHER, FLAT, HARDENED 1.5 8
9 LL5HN014 NUT, HEX, 1.5-6UNC, GRADE 5 16
40
4、 Wrist pin assembly
LL09022 WRIST PIN ASSEMBLY
1 LLCPCP009 PIN COTTER .39x7.9 1

2 LL09012 NUT, WRIST PIN, 3.5-6UN 1
3 LLCPRF001 FITTING, RELIEF, .13NPT 47200 1
4 LL09023 HOUSING 1
5 LLWL010 WASHER, LOCK,1 3
6 LL5HB606 BOLT, HEX, 1-8UNC×3.5,GRADE 5 3
7 LLCPFB005 OIL SEAL, FB14017015 1
8 LL09024 WRIST PIN 1
9 LLCPB008 BEARING 22324CA/C3/W33 1
10 LLCPSW002 SUPPORT WASHER, 5900-475 1
11 LLCPRE003 RETAINING RING, 5100-475 1
12 LL09026 COVER, WRIST PIN 1
13 LL2HB102 BOLT, HEX, .5-13UNC×1.5,GRADE 2 6
14 LLCPGF001 FITTING, GREASE, .13NPT 1610BL 1
41
5、 Gear reducer
42
LLR00104 GEAR REDUCER

1 LLR01117 HSP 1
2 LLR02110 ISP 1
3 LLR03117 LSS 1
4 LLR02111 HSG 2
5 LLR03119 LSG 1
6 LLR04122 BASE ASSEMBLY 1
7 LLR01110 BEARING HOUSING ASSEMBLY OF HSP 1
(SHEAVE SIDE)
8 LLR01112 BEARING HOUSING ASSEMBLY OF HSP 1
(BRAKE SIDE)
9 LLR02107 BEARING HOUSING ASSEMBLY OF ISP 2
10 LLR03120 BEARING HOUSING ASSEMBLY OF LSS 2
11 LLCPGRS001 SHAEVE AND QD HUB (50”6C) 1
12 LL07101 SUPPOET FOR BG 1
13 LLR06046 BRAKE WHEEL ASSEMBLOY 1
14 LLR04107 VIEW COVER 1
15 LL2HB061 BOLT,HEX,0.4375-14UNC×1,GRADE 2 10
16 LL5HN014 NUT, HEX, 1.5-6UNC,GRADE 5 24
17 LL5HB904 BOLT, HEX 1.5-6UNC×7,GRADE 5 12
18 LL2HN010 NUT, HEX, 1 -8UNC,GRADE 2 4
19 LL2HB612 BOLT, HEX 1-8UNC×5.875,GRADE 2 2
20 LLWFN010 WASHER, FLAT,NARROW,1 2
21 LLR01110 BEARING HOUSING OF HSP
1
(SHEAVE SIDE)
22 LLCPB004 BEARING NU2324EM/C3 2
23 LLCPFB001 OIL RING FB120×150×12 2
24 LLCPWHM001 RTNG RING WHM-1025 2
25 LLR01112 BEARING HOUSING OF HSP
1
(BRAKE SIDE)
26 LLR02107 BEARING HOUSING OF ISP 2
27 LLCPB005 BEARING NU2328EM/C3 2
28 LLCPWHM002 RTNG RING WHM-1175 2
29 LLR03120 BEARING HOUSING OF LSS 2
30 LLCPB006 BEARING NJ2240EM/C3 2
31 LLCPFB002 OIL RING FB200×230×15 2
43

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Pump Operation Manual

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OPERATION MANUAL FOR PUMPING UNITS

MANUFACTURED FOR LIBERTY LIFT SOLUTIONS LLC

SHANDONG JINZHOU PETROLEUM EQUIPMENT CO.,LTD.

CHAPTER 1 SAFETY PRECAUTION....................................1

CHAPTER 1 SAFETY PRECAUTION

PRACTICE SAFETY FIRST

Be aware of all power line positions prior to beginning installation or maintenance on or

CHAPTER 2 GENERAL INFORMATION

EXPLANATION OF PUMPING UNIT DESIGNATIONS

BOLT TIGHTENING TORQUE VALUES

THE FOLLOWING TABLE GIVES RECOMMENDED TIGHTENING TORQUES.

TABLE 1. RECOMMENDED TORQUE VALUES

TABLE 2 MAIN SPECIFICATIONS

Balance Weight of crank 2×4906 lbs

CHAPTER 3 STRUCTURE INTRODUCTION

FIG.1 PUMPING UNIT STRUCTURE

1. Horse head 2. Walking Beam 3. Polished Rod Hanger

4. Saddle Bearing Assembly 5. Samson Post 6. Equalizer Bearing Assembly

7. Equalizer Beam 8. Pitman 9. Wrist Pin Assembly

13. Brake Assembly 14. Crank Guard 15. Belt Guard

3) Polished Rod Hanger

4) Saddle Bearing Assembly

6) Equalizer Bearing Assembly

9) Wrist Pin Assembly

10) Crank Assembly

11) Gear Reducer

Warning: The soil under concrete foundation must be compacted. Concrete

13) Brake Assembly

14) Crank Guards

Pumping Unit Installing Orientation

Fig.2 Foundation of EG640-365-168 WFLP

2. SETTING AND ALIGNING THE BASE

Step 2: Adjust substructure body levelness. Vertical levelness

3. GEAR REDUCER INSTALLATION

Step 3: Tighten all bolting on gear reducer and bolting on sub-base.

4. BRAKE RELEASE AND ADJUSTMENT PROCEDURE

Step 1: Release the brake by loosening the brake lockout nut.

Step 2: To adjust the brake pads, continue loosening the brake

Step 3: Tighten the nuts and adjustment bolts to maintain proper

5. BRAKE LINKAGE ASSEMBLY PROCEDURE

Step 7: Tighten all yoke nuts to maintain adjustments.

6. INSTALLATION OF COUNTERWEIGHTS ON CRANKS

Step 2: Insert a chain or cable through the holes in the

Step 3: Install the "T" bolts in the slot of the crank.

Step 4: Set the counterweight on the bolts.

8. ASSEMBLY AND INSTALLATION OF LADDER TO STRUCTURE

9. INSTALLATION OF PITMAN ARMS TO EQUALIZER

Step 7: After installation，add grease to Equalizer holes.

10. INSTALLATION OF WALKING BEAM TO EQUALIZER

Step 2: Position the flanges on the equalizer assembly to align with

Step 1: Position saddle bearing on the ground with larger mounting

12. INSTALLATION OF WALKING BEAM ASSEMBLY TO STRUCTURE

13. INSTALLATION OF WIRELINE ASSEMBLY TO HORSEHEAD

open end facing the polish rod.

Step 4: Install the horse head adjusting bolts.

14. INSTALLATION OF HORSEHEAD TO WALKING BEAM

15. INSTALLATION OF PRIME MOVER

16. V-BELT INSTALLATION AND ALIGNMENT

Install a matched set of belts, always using the inside grooves if

CHAPTER 5 OPERATION AND ADJUSTMENT

1) CHECK BEFORE INITIAL OPERATION

3) AFTER 24 HRS. OPERATION

4) AFTER FIRST TWO WEEKS OPERATION