Whitmore EasiPump Instruction Manual

EasiPump / EasiPoint
Installation & Maintenance Manual
TRACK MOUNTED, MECHANICAL, RAIL AND WHEEL
FLANGE LUBRICATOR SYSTEM
Model Variants:
1 Blade System • 2 Blade Systems
EasiBlades • EasiCheck Blades
Systems shown without reservoirs, (range of reservoirs available)
The EasiPump and EasiPoint systems are very similar. The difference is the pump plunger where the
EasiPoint provides 40% of the pump output for the same plunger movement compared to the EasiPump.
EasiPoint Product intended for switch rail lubrication on turnouts.
EasiPump Product intended for running rail curve lubrication.

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Contents
1General 3
2Product Transport / Storage 3
3Main Component Definitions 3
4Site Preparation 5
5Preparation of Main Components for Installation 6
6Installation 7
6.1 Single and Two Blade Systems 7
6.2 Fitting the Pump Rail Clamp, Flat Bottom Rail 7
6.3 Fitting the Pump Unit 7
6.4 Fitting the Feed Hose and Reservoir 8
6.5 Setting the Pump and Plunger Height 8
6.6 Filling the System 9
6.7 Air Lock / Bleeding 9
6.8 Test the Pumping System 9
6.9 Installing EasiBlades 10
6.10 Installing Check Rail Blades in place of Blades 11
6.11 Fitting the Delivery Hoses 12
6.12 Fill the Hoses and Blades 12
7Routine Maintenance 13
7.1 Measuring the Reservoir 13
7.2 Checking for Leaks 14
7.3 Cleaning the Lubricator and Surrounding Site 14
7.4 Measuring the Plunger Height 14
7.5 Checking for Airlocks 15
7.6 Checking for Defective Plunger and Plunger Spring 15
7.7 Checking for a Defective Outlet Non-return Valve 15
7.8 Inspection of the Blades 16
7.9 Filling the Reservoir 16
7.10 Periodic Replacement of Components 16
8Parts List 17
9Basic Installation Tool Kit 17
10 Exploded Views of System Elements 18
10.1 EasiPump Schematic 18
10.2 EasiPoint Schematic 21
10.3 Blades 23
10.4 Reservoirs 25

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1 General
Health & Safety legislation requires that LubriCurve rail lubricators are fitted by trained personnel
only; warranty will also be affected if un-trained teams work on the LubriCurve products.
Whitmore Rail provide training courses.
A general instruction sheet is included with each LubriCurve pump supplied, this Manual provides
more complete information and should be used to support training provided by Whitmore Rail.
This Instruction Manual is intended to be generic and concentrates on LubriCurve systems to suit Flat
Bottom rail types.
Only lubricator grease approved for use by Whitmore Rail can be used in the LubriCurve system. Use
of other greases will invalidate warranty.
2 Product Transport / Storage
Goods are packed and delivered to requested address in a form that is suitable for the product given
good practice in the off-loading by the receiving company.
LubriCurve 50 systems are delivered on the basis that they will be installed quickly.
Systems are not intended for outside storage, equipment should be off loaded and stored inside a
secure watertight building until required for installation.
3 Main Component Definitions
Reservoir
The reservoir is the cylindrical grease container that stores the grease.
Internal springs and piston forces the grease into the lubricator pumps via
feed hoses.
Non-Return Filling
Valve
The non-return filling valve is fitted to the reservoir; this is where the grease is
pumped into the reservoir (when fitted to the lubricator) via a suitable hand
operated or motorised pump.
Feed Hose
This is the hose linking the reservoir to the pump inlet.
The hose is secured using a hose clip at each end of the hose.
The feed hose transfers the grease from the reservoir to the pump inlet.
Grease Inlet
This is part of the pipework that links the feed hose to the pump inlet.
Pump Unit
The pump unit consists of a pump body and is mounted to the rail by the rail
clamp and pump support brackets.

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Plunger Height
Adjustment Screw
A special locking screw operated with a 2.5mm Allen key that is adjusted from
the top of each pump body to adjust the height of the plunger. A pressure pad
operates on the side of the adjuster screw.
The higher the plunger in relation to the top of the rail the greater the grease
output
Plunger Return
Spring
The spring returns the plunger to its static position after the plunger has been
depressed by the train wheel (or manually).
Pump Body
Pump contains:
1 plunger (complete with integral non return valve)
1 plunger height adjustment screw
1 plunger return spring
1 grease outlet non-return valve
1 bleed screw
1 delivery hose outlet pipe
1 pump support bracket.
The grease is delivered from the reservoir via the feed hose and fills the
primary chamber of the pump unit. When the system is primed the grease
then fills the secondary chamber via the plunger integral non-return valve.
Once the plunger is depressed by the train wheels, (or manually) the grease is
transferred via the outlet non-return valve to the outlet pipe and then through
to the delivery hoses.
On the return stroke of the plunger its integral non-return valve opens and
allows grease to flow into the secondary chamber from the primary chamber.
Grease Outlet non-
Return Valve
The non-return valve acts as a stop valve, preventing the grease in the Blade
path from being drawn back into the pump body as the plunger rises.
Once the plunger is depressed by the train wheel, (or manually), the grease is
transferred from the secondary chamber through the outlet non-return valve,
permitting grease to flow through to the Blade via the delivery hoses.
Bleed Screw
Once open, any air trapped in the secondary chamber is able to be released
when the plunger is operated or fully raised.
Delivery Hose
There is a specific length of delivery hose supplied with each lubricator, which
has to be cut to fit between a pump body and a Blade assembly.
The hose is secured using a hose clip at each end of the hose.
The delivery hose transfers the grease from the pump outlet to the Blade inlet.
Blade (Grease
Dispensing Unit)
The Blade has multiple ports at the top of the grooved plate, which allows the
grease to be delivered to the gauge corner and/or gauge face of the rail for
the train wheels to pick up and spread along the curve.

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4 Site Preparation
To install an EasiPump, the ballast has to be cleared to allow the reservoir to be seated correctly in a
position, clear of the trains. There also needs to be sufficient clearance made in the ballast for the
feed hoses and the rail clamps that secure the pump and the two Blades.
The equipment needed for this work is:
oA shovel or ballast fork whichever one is the most suitable.
oAll relevant P.P.E. needed to carry out the works safely.
The lubrication systems outlined are heavy and care should be taken in general safe mechanical
handling of the units to the install site. Two people should handle pump storage boxes and reservoirs,
carry kits are available for the reservoir.

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5 Preparation of Main Components for Installation
Application
Ensure the correct pump type has been selected for the application; part
numbers and descriptions are included on each pump case.
Packing Case
Cases are delivered damage free and complete. Ensure the case has not been
damaged during storage or transport to rail site, should the case be broken
the contents should be carefully checked with reference to the contents list
included within each pump packing case.
Pump Unit
Visually inspect for any casting defects that will affect its operation.
Ensure that the pump unit brackets are not damaged.
Ensure that the outlet non-return valve at the base of the pump body is fully
tightened into each pump body.
Ensure that the bleed screw is fully tightened.
Ensure that the pump body has one grease outlet pipe attached.
Ensure that the plunger is able to be depressed manually and returns freely.
Blade
Ensure that it is not bent or damaged and all ports are free from blockages.
Ensure that all bolts are present and are fitted securely.
Ensure that the hose inlet tails, which the delivery hoses attach to, are in place
and are not damaged.
Rail Clamps
Ensure that both pump and Blade clamps are not damaged.
Ensure that the threads on the hook bolts are not damaged.
Hoses (feed and
delivery)
Ensure that the hoses are intact and free of holes and splits.
Reservoir
Visually inspect for any casting defects that will affect its operation.
Ensure that all bolts are present and are fitted tightly.
A non-return filling valve is fitted tightly and the internal ball is free moving.
Serial Numbers
Pumps and Reservoirs are supplied with unique serial numbers, these should
be recorded prior to installation and recorded on installation record sheets as
required

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6 Installation
6.1 Single and Two Blade Systems
The basic EasiPump can be fed with grease from a range of spring pressure grease reservoirs. Similarly
single or pairs of running rail or check rail blades can be fitted to the output.
The basic installation procedure steps are:
Fit the EasiPump
Fit the reservoir
Fit the blades
This manual covers the basic principles required for pump and blades.
6.2 Fitting the Pump Rail Clamp, Flat Bottom Rail
6.2.1 Once the bed that the pump is to be fitted to has
been identified, lay the pump unit on the ballast
adjacent to the rail (on the cess side) and with the
pump hinged away from the rail.
6.2.2 With the pump body loose and hinged away from
the rail slide the rail clamp over the foot of the rail
from the cess / field side.
6.2.3 The hook bolt is fitted under the rail with the hook
clasping on the foot of the rail on the 4’ side with
the threaded part inserted through the hole at the
base of the clamp.
6.2.4 The washers and nut are then fitted to the hook bolt and fastened tight, the flat washer
and M16 Nyloc nut should be used.
6.2.5 Using the 1lb hammer strike the rail clamp on each upright lug to ensure it is fully bedded
on the rail foot. Tighten all fasteners.
6.3 Fitting the Pump Unit
6.3.1 Rotate the pump in relation to the rail clamp and set the top of the pump body against the
rail and 11mm below the crown of the head.
6.3.2 The pictures above show the requirement. Use the setting gauge LCS104-02 to achieve the
required height.

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6.3.3 If the pump needs to be lowered then tap the pump
body down using the shaft of a hammer or strike the
face of the left side support bracket.
DO NOT STRIKE THE ALUMINIUM PUMP BODY
WITH A HAMMER AT ANY STAGE.
6.4 Fitting the Feed Hose and Reservoir
6.4.1 Slide the 25mm bore hose over the brass hose tail on
the pump and secure with the hose clip provided.
Tighten the hose clip.
6.4.2 Dig out the ballast so that the reservoir feed hose
curves away from the EasiPump and clears the rail clip
and sleeper without any kinks / restrictions to the
hose.
6.4.3 Bury the reservoir at an angle and approx. half its
depth to secure it in position, (see front cover picture).
6.4.4 Slide a feed hose clip over the open end of the feed hose and fit onto the angled pipe.
Tighten the hose clip.
6.4.5 The feed hose may need to be cut due to the local conditions.
6.4.6 Position the reservoir into space dug in the ballast ensuring that there are no kinks in the
feed hose.
6.5 Setting the Pump and Plunger Height
6.5.1 The height of the plunger is adjusted by first loosening
the M8 lock screw on the side of the pump and then
rotating the adjuster screw in the top of the pump.
6.5.2 Loosen the M8 locking screw nut and then turn the
M8 hex screw a few turns, it is not necessary to
remove.
6.5.3 Using a suitable gauge / measurement device and a
2.5mm Allen key, raise the plunger to the initial
setting height of 0.5mm above the top of the rail.
Note: subsequent adjustment is usually necessary to
adjust grease output to suit local traffic / wheel
pattern. The typical range will be between 0 and 1mm
relative to crown of the rail head, in extreme cases it is
also permissible to set below rail head where worn
wheels are the cause of over greasing.
6.5.4 A setting gauge (Part No. LCS104-06) is available to
allow this measurement to be accurate.

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6.5.5 When the plunger height is correct tighten the pressure pad against the adjuster screw by
retightening the locking screw lightly (do not over-tighten)
6.5.6 Should further adjustments be required then the procedure should be repeated having
first loosened the pressure pad screw.
6.5.7 Ensure the plunger and adjusting screw cannot contact the passing train during this time.
6.6 Filling the System
6.6.1 Once the reservoir is fitted to the pump unit fill it up with grease:
1. Remove the filler dust cap and store it safely.
2. Attach a suitable drum pump to the 1” Snaplock filling point and secure locking arms
in clamp position.
3. Operate the hand pump measuring piston depth periodically to ensure the reservoir
is not overfilled. On Whitmore Rail products the following measurements are
applicable.
Standard Reservoir (LCS102-01) from the reservoir back plate to the rear most surface of the
piston; see Installation Manual Section 7.1 and 7.2.
Full is 80mm
Empty is 280mm
Small Reservoir (LCS102-30) from the reservoir back plate to the rear most surface of the
piston; see Installation Manual Section 7.1 and 7.2.
Full is 50mm
Empty is 200mm
IMPORTANT NOTE: Do not overfill the reservoir
4. Remove the hand pump and replace the reservoir dust cap.
6.7 Air Lock / Bleeding
6.7.1 Once the reservoir is full, open the bleed screw
(do not remove) until grease flows from the
screw. If necessary operate the plungers until
grease starts flowing.
6.7.2 Once the grease is flowing hold down the plunger
fully and close the bleed screw, this process
prevents air from being drawn back into the
system.
Note: A reservoir spider (Part No. LCS102-04) should be
available at this stage should it be necessary to lock the
reservoir piston back, if the hose or coupling need to be removed for any reason.
6.8 Test the Pumping System
6.8.1 Using a 10mm “T” bar or other suitable tool depress the plunger (not completely down)
until the grease flows from the outlet pipe.
IMPORTANT NOTE: Do not strike the plunger with a hammer at any stage.

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6.9 Installing EasiBlades
6.9.1 EasiBlades are supplied as complete single
units. From the 4’ / Gage and midway
between Sleepers / Ties slide the base (W
bracket) over the rail foot as shown. Locate
the hook bolt around the opposite side of
the foot and tighten the single Nyloc nut.
Fully bed the base onto the rail using a
hammer on the vertical faces of the ‘W’
bracket. Retighten the Nyloc nut.
6.9.2 The blades are provided in left and right
hand forms; the difference being the direction the hose tail points, the correct layout is
shown in the adjacent picture, outer pairs with hose tails pointing towards each other.
6.9.3 Tilt the blade up so that the blade tip is towards the rail head and as high as possible,
lightly tighten the two pivot bolts.
6.9.4 Decide the required blade height and tap the steel lugs on the blade down using a hammer
to achieve the required height. The setting gauge described previously should be used to
verify heights.
6.9.5 There may be a slight gap between the tip of the blade and the rail. To close this gap tap
the corner of the lug as necessary, do not hammer the blade itself.
Note: Strike the bracket to angle the blade as shown on the red arrow.
6.9.6 Repeat the process for each EasiBlade.

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6.10 Installing Check Rail Blades in place of Blades
The procedure is similar to the standard Blade installation on the high rail. The procedure outlined
covers Bull Head and 113, 109, 110 Flat Bottom Check Rail. After completing this Section, proceed from
Section 6.11 as filling and priming principals are the same for Check Rail blades and Blades.
Bull Head Check Rail (Figure 1)
Flat Bottom Check / Restraining Rail (Figure 2)
U69 / UIC33 Check / Restraining Rail (Figure 3)

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6.10.1 Fit the rail clamps to the Check Rail generally following procedures outlined in the previous
sections. The Blade fixing studs on the clamps should be oriented towards the 4’, clamp
spacing to suit the check rail blades and the full assembly located midway between the
sleepers.
6.10.2 Locate the Check Rail assembly on the two rail clamp studs and tighten the two M16
fasteners securely.
6.10.3 The blade has vertical and horizontal adjustment through setting of the M16 fastenings on
the support bracket. Arrange the blade so that the exit ports are between 1 and 2mm from
the Check Rail face and the blade is horizontal, lock securely in that position.
6.11 Fitting the Delivery Hoses
6.11.1 Fit one end of a delivery hose to the hose tail inlet on the Blade with a hose clip and
measure the other end of the hose to the grease outlet tail of the pump body, cut the hose
and secure it with a hose clip. Ensure that the hose runs under the rails.
6.11.2 Repeat the procedure for the other hose.
6.12 Fill the Hoses and Blades
6.12.1 Using the 10mm “T” bar keep depressing one of the plungers until grease appears onto the
top of the Blade. Do not fully depress plunger, maintain a minimum 1mm clearance with
the pump body.
6.12.2 Repeat for the other Blade.

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7 Routine Maintenance
Prior to any maintenance it is necessary to have the following data.
The date that the lubricator was last maintained.
The final depth of the reservoir piston when the lubricator was last maintained.
The plunger height when the lubricator was last maintained.
Any works that were carried out when the lubricator was last maintained that could change the
grease output.
Any work that was identified but not carried out on the previous visit.
7.1 Measuring the Reservoir
7.1.1 This measurement is the only true guide to how much grease the lubricator has used since
it was last visited. It is necessary to have the previous recordings of the last inspection, this
will enable you to make judgements and carry out corrective action if needed without any
guesswork.
7.1.2 Using a ruler, insert it into the centre hole in the front cover of the reservoir, making sure
that the side of the ruler is touching against the side of the hole and that the ruler is at the
same angle of the reservoir (See Figure 4).
7.1.3 When the ruler stops at the rear most face of the piston, check exactly the measurement
(in millimetres) against the face of the front cover at the centre hole.
Figure 4
7.1.4 Record this measurement and compare it to the data that you have brought to site.
7.1.5 By subtracting the final measurement recorded from the last time the lubricator was
maintained from the measurement you have recorded this time would give you the grease
used in millimetres.
7.1.6 The type of lubricator, its installation and rail traffic will determine the volume of grease
used since the lubricator was last maintained. Figure 4 shows Whitmore Rail reservoir
(Part No. LCS102-01) where 1mm of piston displacement equates to 0.12kg of grease.
7.1.7 However do not make any alterations at this stage, as other reasons for incorrect grease
outputs may be the cause.

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7.2 Checking for Leaks
7.2.1 The lubricator should be checked for leaks. With some leaks it will be necessary to take the
leak into consideration in regards to the grease output that was registered.
7.2.2 Leaks on the primary side (i.e. feed hoses or inlet assembly) of the lubricator will cause an
increase in grease output that is not due to the settings of the lubricator.
7.2.3 Tighten any hose clips or nuts / bolts / screws that might be the cause of the leak and / or
replace the faulty part that is causing the leak.
7.3 Cleaning the Lubricator and Surrounding Site
7.3.1 It is at this stage that the lubricator must be cleaned. The reasons are that when the checks
are made, you will be able to register measurements and assess the operations of the
lubricator accurately and carry out the works in a cleaner environment. The reason why
the lubricator must not be cleaned before this stage, is that once it is clean, you will have
removed evidence of the leak.
7.3.2 The whole of the lubricator must be cleaned thoroughly.
7.3.3 The site must be cleared of excess grease.
7.3.4 If oil absorbent granules are being used, the existing, soiled granules should be removed
and replaced with fresh granules. This must be done with extreme caution, if the granules
are allowed to get into the lubricator system via the filling valve, the system may become
blocked or worse the non-return valve can be held open.
7.3.5 The surrounding rail chairs and clips, all rails in the immediate vicinity and the insulator
pots need to be cleaned. The 3rd and 4th rail are required to be cleaned to ensure they
are free of grease and dirt, this is to avoid causing a fire risk and hazardous under footing.
7.3.6 Do not attempt to clean live traction current rails with the current switched on.
7.4 Measuring the Plunger Height
7.4.1 This section is for the initial measurements of the plunger height. The height to be
measured is the distance between the levels of the top of the plunger head, and the crown
of the rail.
7.4.2 The plunger heights must be measured and recorded. The plunger height must be
measured to the nearest 0.25 of a millimetre.
7.4.3 If the lubricator has not used the amount of grease that is required as expected since the
last time that it was maintained.
7.4.4 Check that the plunger height is the same as when the lubricator was last maintained.
7.4.5 You may find that the plunger height has changed due to loose bolts on the pump unit
bracket causing the pump unit to move, check the bolts and tighten if necessary. If
necessary reset the plunger height once all the other checks have been carried out.
7.4.6 If the plunger height is lower than previously although the bolts are all tight, check that the
plunger has not become flat, if so change them, also the plunger may be stuck down due
to defective springs, this will be detected by the plunger operation test later in this
Manual.
7.4.7 If the plunger height has been reset on this visit record the new height.

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Note: If the plunger is being raised, it should only be raised by 0.25mm at a time and must be inspected
on the following shift. However, if the plunger height is known to have dropped they may be
reset to their original height, but a follow up inspection must still be made on the following shift.
The Plunger height should be adjusted up (to increase grease output) or down (to decrease
grease output), to suit local traffic / wheel pattern.
7.5 Checking for Airlocks
7.5.1 The following shows steps taken to check for airlocks.
Remove the delivery hose from the pump outlet.
Using the 10mm “T” bar, depress the plunger downwards several times.
If the plunger has no resistance, and / or there is no grease flow, the pump is probably air
locked.
Record the results.
If the test was not satisfactory, clear the air lock. The easiest method is by loosening the air
bleed screw until the groove on the threaded section is exposed. Using the 10mm “T” bar,
depress the plungers downwards several times; do not exceed the permissible plunger travel.
Record the results.
If the attempt to clear the airlock was not satisfactory check that there is a grease flow from
the reservoir.
7.5.2 Air locks that are present on arrival at the lubricator will give you certain information into
why the lubricator has not had a sufficient grease output.
7.5.3 If the lubricator has not used any or enough grease required for that particular lubricator
but air locks are present, plunger must not be raised, as due to the air locks, the lubricator
would have not been working.
7.5.4 If the lubricator has not used any grease, but no air locks are present other corrective
actions should be undertaken.
7.6 Checking for Defective Plunger and Plunger Spring
7.6.1 The operation test of this section should be made into two parts:
Firstly, by using the pump pliers, grip the plunger and move the plunger up and down to ensure
that there is no free movement of the plunger or plunger return spring.
The second test is using the 10mm “T” bar to depress the plunger. Ensure that the return of the
plunger is not too slow and in addition check that it’s returning fully after every depression.
IMPORTANT NOTE: Do not fully depress plunger to avoid damage.
Record the results of the test.
If the test is not satisfactory then the plunger and / or plunger return spring should be changed.
7.7 Checking for a Defective Outlet Non-return Valve
7.7.1 If the grease is flowing onto the spreader bar or out of the pump body outlet ports, when
the delivery hoses are removed, without the plungers being struck, the non-return valve
may be defective.

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7.7.2 If the non-return valve is found to be defective, the valve cannot be repaired and a new
valve is not available the lubricator must be temporarily locked off, if this is not done,
excessive grease will migrate onto the head of the rail.
7.8 Inspection of the Blades
7.8.1 Visually check the Blades for damage and / or wear.
7.8.2 Check that the fastenings are secure.
7.8.3 Depress the plunger, using the 10mm “T” bar and ensure all of the ports on the top face of
the spreader bar are dispersing grease. This will show if there is hardened grease, inside
the Blade and/or if the Blade slots are blocked. Do not fully depress plunger to avoid
damage.
7.8.4 Record your findings and any works carried out.
7.9 Filling the Reservoir
7.9.1 Ensure that the non-return filling valve is clean, place the filling pump nozzle over the non-
return filling valve on the reservoir and pump the handle.
7.9.2 Do not overfill the reservoir.
7.9.3 Record the final reservoir measurements.
7.10 Periodic Replacement of Components
7.10.1 It is recommended that various system items are replaced periodically; exchange will be
dependent on traffic frequency and should be monitored during maintenance visits but as
a minimum should include the following.
Exchange
Frequency
Pump
Springs
2 years
Plunger
2 years
Fasteners
5 years
Hose
Blade and Reservoir Hose
2years
Reservoir
Seals
5 years
Springs
5 years
Filler Valves
5 years

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8 Parts List
Contact Whitmore Rail for advice / availability
9 Basic Installation Tool Kit
A selection of hand tools are suggested to correctly fit and maintain the pumps, specific recommended
Whitmore Rail products are referenced above.
T Handled 2.5mm Allen Key
Ratchet Handle 1/2" Drive
Combination Spanner 24mm
Combination Spanner 13mm
Combination Spanner 15/16"
Socket 7mm 3/8" drive
Socket 13mm 1/2" drive
Socket 24mm 1/2" drive
Socket Long Reach 24mm 1/2" drive
Ball Pein 1lb Hammer
Junior Hacksaw and Blades
Screwdriver 6" x 1/4" flat blade, flared tip
Folding Rule (wood or plastic)
Tool Bag

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10Exploded Views of System Elements
10.1 EasiPump Schematic

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