Whitmore LUBRICURVE 50 Instruction Manual

LUBRICURVE 50
Installation & Maintenance Manual
TRACK MOUNTED, MECHANICAL, RAIL AND WHEEL
FLANGE LUBRICATOR SYSTEM
Model Variants:
2 Blade Systems • 4 Blade Systems
EasiBlades • Standard Blades

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Contents
1General 3
2Product Transport / Storage 3
3Instruction Manual Product Summary 4
4Main Component Definitions 4
5Site Preparation 6
6Preparation of Main Components for Installation 7
7Pump / Reservoir Installation 8
7.1 Two Blade & Four Blade Systems 8
7.2 Fitting the Pump Unit Clamps, Flat Bottom Rail 9
7.3 Application Variation - fitting the pump unit clamps, Bull Head rail 9
7.4 Fitting the Pump Unit 9
Alternative for Bull Head Pumps 10
7.5 Fitting the Feed Hose and Reservoir 11
7.6 Filling the System 11
7.7 Setting the Pump and Plunger Height 12
7.8 Test the Pumping System 13
8Blade Installation 14
8.1 Installing Standard Blade (rail clamp each end) 14
8.2 Application Variation for Bull Head Blade Rail Clamp 14
8.3 Installing the Blades 14
8.4 Application Variation for Other Rail Types 15
8.5 Installing EasiBlades (single central rail clamp) 15
8.6 Installing Check Rail Blades 16
9Final Setting 18
9.1 Fitting the Delivery Hoses 18
9.2 Fill the Hoses and Blades 18
9.3 Fit the Pump Guard 18
10 Routine Maintenance 19
Prior to any maintenance it is necessary to have the following data. 19
10.1 Measuring the Reservoir 19
10.2 Checking for Leaks 19
10.3 Cleaning the Lubricator and Surrounding Site 20
10.4 Measuring the Plunger Heights 20
10.5 Checking for Airlocks 21
10.6 Checking for Defective Plungers and Plunger Springs 21
10.7 Checking for a Defective Outlet Non-return Valve 22
10.8 Inspection of the Blades 22
10.9 Filling the Reservoir 22
10.10 Periodic Replacement of Components 22
10.11 Maintenance Log Sheet Example 24
11 Parts List 25
12 Basic Installation Tool Kit 25
13 Exploded Views of System Elements 26

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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 can 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 and Bull Head rail types, in particular 98,109, 110, 113lb, UIC60 flat bottom rails and 95lb bull
head rail applications.
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.
IMPORTANT:
Maintenance and repair of the lubricator and reservoir should only be carried out
by trained personnel. Compressed springs inside the lubricator may be dangerous
if handled incorrectly.

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3 Instruction Manual Product Summary
Instruction Manual covers installation and maintenance of the mechanical / hydraulic lubricators in the
Whitmore Rail LubriCurve 50 range.
There are many variants to suit different rail sections along with blade types and forms, this manual is
intended to be generic and cover all forms.
Contact Whitmore Rail for any specific model information or assistance.
A variety of parts to assist with installation efficiency are available and such items and their use are
available from Whitmore Rail.
4 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 pipework.
Blade (Grease
Dispensing Unit)
There are generally two or four Blades used with each lubricator, each consisting
of three rectangular plates, back plate middle plate and grooved front plate).
Each Blade is fitted to the rail using two rail clamps, which are secured to the rail
by a hook bolt, nut and washer per clamp.
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.
Delivery Hose
There is one 3-metre length of delivery hose supplied with each lubricator, which
has to be cut into two suitable lengths 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.
Grease Inlet
This is part of the pipework that links the feed hose to the inlet pipe.
Pump Unit
The pump unit consists of two pump bodies (connected by an inlet pipe) and is
mounted to the rail by the pump support brackets via 2 pump rail clamps
Inlet Pipe
The “T” piece assembly connection that links the grease inlet to the two pump
bodies.

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Pump Body
Each 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 / ”T” piece and fills
each pump 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 plungers are 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.
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
There is one plunger return spring in each pump body.
The springs return the plungers to its static position after the plunger has been
depressed by the train wheel (or manually).
Grease Outlet
non-Return
Valve
There is one grease outlet non-return valve, in each pump body. 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
There is one bleed screw on each pump body.
Once open any air trapped in the secondary chamber, is able to be released when
the plunger is operated or fully raised.

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5 Site Preparation
To install a LubriCurve 50 lubricator, 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 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 (typically
28kg) and reservoirs (typically 54kg), carry kits are available for the reservoir (Part No, LCS102-05).

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6 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. Dispose of all packaging responsibly.
Pump Unit
Visually inspect for any casting defects that will affect its operation.
Ensure that both the pump unit brackets are not damaged and that both bolts are
present on each bracket.
Ensure that each outlet non-return valve at the base of the pump body is fully
tightened into each pump body.
Ensure that there is one bleed screw in each pump body and that they are fully
tightened.
Ensure that each 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.
Clamps
Ensure that both pump and Blade clamps are not damaged.
Ensure that the threads on the clamp studs are not damaged.
Ensure that the threads on the hook bolts are not damaged.
Hoses
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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7 Pump / Reservoir Installation
7.1 Two Blade & Four Blade Systems
Two blade systems are generally installed with running rail blades on the high rail with pump / reservoir
also generally on that rail. Four blade systems are generally installed ahead of a series of reversing curves
with two blades on each rail.
Installation of components from either system is covered in this manual but with notes on four blade
installation directly below.
7.1.1 4 Blade Systems
Typical layout is shown in the following images;
one pair of blades to the right of the pump /
reservoir and on the same rail and the second
pair of blades on the far rail and to the left of the
pump / reservoir.
Each pair of blades has a ‘T’ piece midway
between the blades and the hose from the T’s
vertical leg routes to each of the pump bodies.
The hose between each blade and the T must be
of identical length.
Plunger heights are generally set to 1mm (see 7.7) on 4 blade systems.
7.1.2 2 Blade Systems
A typical layout has blades to the right of the pump / reservoir and one to the left on the same
rail.
The hose runs from each blade to the nearest pump body.
Plunger heights are generally set to 0.5mm (see 7.7) on 2 blade systems.

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7.2 Fitting the Pump Unit Clamps, Flat Bottom Rail
7.2.1 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) to show the positions that the
pump unit clamps need to be fitted.
7.2.2 Locate the 70mm long special hex bolts
through the upper holes of the clamp with
the hexagon head located in the clamp
slot. Both pump unit clamps can now be
fitted to the rail.
7.2.3 The main part of the clamp is fitted on the
field (outside) side of the rail with the
threaded stud at the top and facing away from the rail.
7.2.4 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.
7.2.5 The washers and nut are then fitted to the hook bolt and fastened tight. Bed the clamp
fully on the rail foot by striking the clamp base with a hammer (do not damage the rail foot
or the clamp thread). Retighten the Nyloc nut.
Repeat for the second clamp.
7.3 Application Variation - fitting the pump unit clamps, Bull Head rail
7.3.1 Rail clamps are of a different form for the Bull Head Rail. The clamps consist of two
sections that fit around the rail flange.
7.3.2 The main part of the clamp (hole and machined slot) is fitted on the field (outside) side of
the rail. Locate the 70mm (3”) long special hex bolts through the upper holes of the clamp
with the hexagon head located in the clamp slot before fitting to rail.
7.3.3 The rear half of the clamp is fitted under the rail with the 160mm long bolt inserted
through the hole at the base and then through the front clamp.
7.3.4 The washers and nut are then fitted to the hook bolt and fastened tight. Bed the clamp
fully on the rail foot by striking the clamp base with a hammer (do not damage the rail foot
or the clamp thread). Retighten the Nyloc nut.
Repeat for the second clamp.
7.4 Fitting the Pump Unit
7.4.1 Using a 13mm spanner, loosen the screws on the
inner face of the pump, ¼ turn is sufficient. This
screw applies locking pressure to the plunger
adjuster screw via a nylon pad. Note that on pre
2004 models a 4mm Allen Key is required in place
of the 13mm spanner.
7.4.2 When initially delivered the pumps will be
supplied with plungers set at a nominal height of
11mm above the pump body, the head of the
5mm special screw will be visible within the pump body.

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7.4.3 A 2.5mm Allen Key is used to adjust the plunger height
to a maximum. Note: screws must not be adjusted to
this height, since this may result in damage when train
wheels pass.
Prior to January 2004 the side pressure pad was not used.
Note: the adjusting screws are designed for use and adjustment
during initial installation only, the adjusting screws include an
anti-vibration feature to maintain the setting. Should further
adjustment be needed then the screw should be unwound to clear the pump body, oil / grease
contamination removed and Loctite 222 applied to the thread prior to re-fitting. New adjusting
screws can be obtained from Whitmore Rail, (see parts list LCS200-22).
7.4.4 Hand tighten the two brass coloured swivel nuts between the pump bodies with the inlet
pointing down and out. This will draw the pump bodies together.
7.4.5 Slightly loosen the two M8 bolts on each pump bracket, fit the pump unit onto the clamp
studs. Place M16 packing washers over the Rail Clamp stud and behind the pump bracket
such that the pump bracket is not strained on tightening of the fixings and that the pump
body is touching the railhead.
7.4.6 Push the pump unit down as low as possible, fit one M16 flat washer and full nut to each
stud and tighten.
7.4.7 Ensure the plunger and adjusting screw cannot contact the passing train during this time.
7.4.8 Fit the grease inlet to the pump inlet ‘T’piece (between the two pump bodies) and tighten
the ‘T’Piece nut ensuring that the inlet is perpendicular to the rail. This connection must
be tight to avoid future leakage; PTFE tape or Loctite 542 hydraulic thread sealant can be
applied to enhance the joint integrity.
7.4.9 Push the grease inlet down until it almost touches the
foot of the rail and tighten the two remaining ‘T’piece
nuts. This connection must be tight to avoid future
leakage.
Alternative for Bull Head Pumps
The fitting process is the same for Bull Head pumps; the
product differences are with the pump support bracket.

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7.5 Fitting the Feed Hose and Reservoir
7.5.1 Slide a feed hose clip over one end of the feed hose and fit onto the outlet pipe of the
reservoir. Tighten the hose clip.
7.5.2 Dig out the ballast so that the reservoir outlet is in line with the inlet of the angled pipe
that is fitted to the pump. Bury reservoir at angle and approx. half depth to secure it in
position, (see front cover picture).
7.5.3 Slide a feed hose clip over the open end of the feed hose and fit onto the angled pipe.
Tighten the hose clip.
7.5.4 The feed hose may need to be cut due to the local conditions.
7.5.5 Position the reservoir into the space dug in the ballast ensuring that there are no kinks in
the feed hose.
7.6 Filling the System
7.6.1 Once the reservoir is fitted to the pump unit, fill it up with grease:
Remove the filler dust cap and store safely.
Attach a suitable drum pump to the 3/4” snaplock filling point and secure locking arms in the
clamp position.
Operate the hand pump measuring piston depth periodically to a reading of 80mm from
reservoir front plate to rear most surface of piston.
Do not overfill the reservoir
Flat Back Plate (older reservoirs) Top Hat Back Plate (newer reservoirs)
Full 80mm Full 80mm
Empty 225mm Empty 280mm
Remove the hand pump and replace the reservoir dust cap.
7.6.2 Once the reservoir is full, open the two brass bleed screws until grease flows out of the
screw grooves. If necessary operate the plungers until grease flows.
7.6.3 Once the grease is flowing hold down the plunger fully and close the bleed screws, this
process prevents air 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.

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7.7 Setting the Pump and Plunger Height
7.7.1 Error! Reference source not found.A Whitmore
Rail pump setting tool will assist this process
(Part No. LCS104-02). Position the pump setting
tool over the top of the plunger so that the short
angled piece is pointing down towards the top of
the pump body. Using a 2.5mm Allen key lower
the plunger until the short section of the tool is
touching the top of the pump body.
Alternatively, a similar procedure should be followed so
that the top of the plunger is set 11mm above the pump
body.
7.7.2 Loosen the two pump unit M16 support bracket
nuts.
7.7.3 Raise both pumps until the tops of the plungers
are level with the top of the rail using a plunger
setting gauge (not supplied) and tighten the nuts.
7.7.4 Rotate the pump bodies in relation to the pump
bracket to lean the plungers towards the
railhead, then secure the two M8 fixings on each
pump body.
7.7.5 Using a suitable gauge / measurement device
and 2.5mm Allen key, raise the plungers to their
initial setting height of 0.5mm above the top of
the rail. Note: Subsequent adjustment is usually
necessary to the adjust grease output to suit local
traffic / wheel pattern. The typical range will be
between 0 and 1mm relative to the top 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.
7.7.6 When the plunger height is correct, tighten the
pressure pad against the adjuster screw using the
M8 hex bolt on each inner face of the pump body
(do not over-tighten). Tighten the M8 Lock nut
against the pump body to lock it in place.
Note: On pre 2004 systems the M8 hex bolt was
an M8 Allen bolt requiring a 4mm Allen Key.
7.7.7 Should further adjustments be required then the
procedure should be repeated having first
loosened the pressure pad screw.

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Note: Prior to January 2004 the pressure pad system was not fitted. The adjusting screws
include an anti-vibration feature to help maintain height setting. The screws have a thread
locking patch towards the top of the thread and require that additional thread locking
compound; Loctite 222 (Whitmore Rail Part No. LCS200-69) is applied to the thread before
screwing into the pump body.
Similarly, should further adjustment be needed then the screw should be unwound to clear
the pump body, general oil / grease contamination removed and Loctite 222 (Whitmore
Rail Part No. LCS200-69) applied to the thread prior to re-fitting. New adjusting screws can
be obtained, (see parts list LCS200-22).
A plunger setting gauge is available from Whitmore Rail should that be preferred (Part No.
LCS104--06).
7.8 Test the Pumping System
7.8.1 Using the wood shaft of a suitable hammer or other suitable tool depress one of the
plungers (not completely down) until the grease flows from the outlet pipe. Do not strike
the plunger with a hammer at any stage. If required the Whitmore Rail pump setting tool
incorporates features that restrict total plunger travel (Part No. LCS104-02).
7.8.2 Repeat for the other pump.

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8 Blade Installation
8.1 Installing Standard Blade (rail clamp each end)
8.1.1 Once the position that the Blade is to be
fitted to has been identified, lay the Blade
unit adjacent to the rail (on the 4’ side) to
show the positions where the Blade clamps
need to be fitted.
8.1.2 Both Blade clamps can now be fitted.
8.1.3 Locate the 50mm (2”) long special hex bolts
through the upper holes of the clamp with
the hexagon head located in the clamp slot.
The main part of the clamp is fitted on the 4’
side of the rail with the thread at the top and facing away from the rail.
8.1.4 The hook bolt is fitted under the rail with the hook clasping on the foot of the rail on the
field side with the threaded part inserted through the hole at the base of the clamp.
8.1.5 The washers and nut are then fitted to the hook bolt and fastened tight. Bed the clamp
fully on the rail foot by striking the clamp base with a hammer (do not damage the rail foot
or the clamp thread). Retighten the Nyloc nut.
8.1.6 Repeat for the second clamp.
8.2 Application Variation for Bull Head Blade Rail Clamp
8.2.1 Blade Rail clamps are different for the Bull Head Rail. Clamps consist of two sections to fit
around the rail flange.
8.2.2 Locate the 50mm (2”) long special hex bolts through the upper holes of the clamp with the
hexagon head located in the clamp slot. The clamp is fitted on the 4’ side of the rail with
the thread stud at the top and facing away from the rail.
8.2.3 The rear half of the clamp is fitted on the opposite side with the M16 x 160 long bolt
inserted under the rail through the hole in both clamps.
8.2.4 The washers and nut are then fitted to the hook bolt and fastened tight. Bed the clamp
fully on the rail foot by striking the clamp base with a hammer (do not damage the rail foot
or the clamp thread). Retighten the Nyloc nut.
8.2.5 Repeat for the second clamp.
8.3 Installing the Blades
8.3.1 Fit the Blade onto the clamps using the M16
flat washer and Nyloc nut onto each clamp
and secure. Hold the Blade against the gauge
face of the rail, if there is a gap between the
back plate and the gauge face of the rail
spacing shims will need to be fitted.
8.3.2 To fit the spacing shims loosen the two M10
bolts that fit the Blade plates to the brackets.
Slip the number of shims needed behind the

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plate and over the threads of the M10 bolts
between the bracket and the Blade
backplate.
8.3.3 Repeat for the other end of the Blade if
necessary.
8.3.4 Set the Blade to the required height below
the railhead using a suitable gauge /
measuring device minimum distance is
18mm. The precise dimension is subject to
rail profile and anticipated wheel wear,
which must be carefully considered. If
required a suitable gauge is available from
Whitmore Rail (Part No. or LCS104-06),
showing setting with QHi/Whitmore Rail
gauge).
8.3.5 Repeat from 8.3.1 for the remaining blades.
8.4 Application Variation for Other Rail Types
8.4.1 The fitting process is the same for the Bull
Head and UIC60 style Blades; only the Blade
bracket is different.
8.5 Installing EasiBlades (single central rail clamp)
8.5.1 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.
8.5.2 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.
8.5.3 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.

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8.5.4 Decide the required blade height and tap the steel lugs on the blade vertically down evenly
using a hammer to achieve the required height. The setting
gauge described in Section 8.3.4 should be used to verify the
heights.
8.5.5 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.
8.5.6 It is important that the lugs are a tight fit over the vertical
face of the rail clamp. If there is any clearance before
tightening then insert suitable M16 washers between the
two items to reduce clearance.
8.5.7 Repeat process for each EasiBlade.
8.6 Installing Check Rail Blades
The procedure is similar to a standard Blade installation on the high rail. Confirm that the check rail
blades are fitted only to the check rail. Note: Rails can take several forms including bull Head, Flat
bottom and U69 / UIC33. After completing this Section proceed from Section 9as filling and
priming principals are the same for Check Rail blades and Blades.
Bull Head Check Rail
Flat Bottom Check / Restraining Rail

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U69 / UIC33 Check / Restraining Rail
8.6.1 Fit the rail clamps to the Check Rail generally following procedures outlined in Sections 8,
referenceError! Reference source not found. for Bull Head rail, Flat Bottom Check /
Restraining Rail, U69 / UIC33 Check / Restraining Rail. Blade fixing studs on the clamps
should be oriented towards the 4’, clamp spacing to suit check rail blades and the full
assembly located midway between sleepers.
8.6.2 When fitting TOR rails with insufficient clearance between the foot of the running rail and
foot of the check rail then a rail clamp is fitted to each rail and long stud in between
passing under the two rails. The check blade must be located at the check block to avoid
over stressing the between the rail fastener.
8.6.3 Locate the Check Rail assembly on the two rail clamp studs and tighten the two M16
fasteners securely.
8.6.4 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.

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9 Final Setting
9.1 Fitting the Delivery Hoses
9.1.1 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.
9.1.2 Repeat the procedure for the other hose.
9.2 Fill the Hoses and Blades
9.2.1 Using the wood shaft of a suitable hammer keep depressing one of the plungers until
grease appears at the Blade. Do not fully depress plunger, maintain a minimum 1mm
clearance with pump body.
9.2.2 Repeat for the other Blade.
Alternative
The operation can be made more efficient by using the Blade priming kit available from Whitmore
Europe (Part No. LCS102-08).
Prior to filling the delivery hose to the pump body outlet.
Insert the filler connector into the free end of the delivery hose and clamp with the provided
hose clip.
Connect the reservoir hand pump and operate until grease starts to exit the Blade ports.
Remove the priming kit from the hose.
Connect the hose to the pump body outlet.
Repeat for the second Blade.
Revert to Section 9.2 for final priming.
9.3 Fit the Pump Guard
9.3.1 Place the tamper bar over the two studs that
are on the pump clamps.
9.3.2 Fit the washers and nuts and tighten.

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10Routine 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 heights 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.
10.1 Measuring the Reservoir
10.1.1 This measurement is the only true guide
which indicates how much grease the
lubricator has used since it was last
visited. It is necessary to have the
previous recordings of the last inspection
since it will enable you to make
judgements and carry out corrective
action if needed without any guesswork.
10.1.2 Using a ruler, insert it into the centre
hole in the front cover of the reservoir
(see side image), making sure that the
side of the ruler is touching against the
side of the hole and the ruler is at the same angle that the reservoir is at.
10.1.3 When the ruler stops at the rear most face of the piston, check exactly the measurement
(in millimetres) against the face of the rear cover at the centre hole.
10.1.4 Record this measurement and compare it to the data that you have brought to site.
Important Note: Do not overfill the reservoir
Flat Back Plate (older reservoirs) Top Hat Back Plate (newer reservoirs)
Full 80mm Full 80mm
Empty 225mm Empty 280mm
10.1.5 By subtracting the final measurement recorded from the last time the lubricator was
maintained from the measurement you have recorded this time will give you the amount
of grease used in millimetres.
10.1.6 The type of lubricator, its installation and rail traffic will determine the volume of grease
used since the lubricator was last maintained. For 1mm of piston displacement equates to
0.12kg of grease associated to Whitmore Europe’s reservoir (Part No. LCS102-01).
10.1.7 However do not make any alterations at this stage, as other reasons for incorrect grease
outputs may be the cause.
10.2 Checking for Leaks
10.2.1 The lubricator should be checked for leaks. In case there are leaks, it will be necessary to
take the leak into consideration in regards to the grease output that you have noted.

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10.2.2 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.
10.2.3 Tighten any hose clips or nuts / bolts / screws that might be causing the leak and / or
replace the faulty part that is causing the leak.
10.3 Cleaning the Lubricator and Surrounding Site
10.3.1 At this stage the lubricator must be cleaned. The reasons are that when the checks are
made, you will be able to note 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.
10.3.2 The whole lubricator must be cleaned thoroughly.
10.3.3 The site must be cleared of excess grease.
10.3.4 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.
10.3.5 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.
Do not attempt to clean live traction current rails with the current switched on.
10.4 Measuring the Plunger Heights
10.4.1 This section is for the initial measurements of the plunger heights. There are two
measurements to be recorded, one for the running on and one for the running off. The
running on and running off are identified by the direction of traffic, the running on being
the first plunger that the train wheels will strike, and the running off being the second
plunger that the train wheels will strike. The height to be measured is the distance
between the top of the plunger head and the top of the crown of the rail.
10.4.2 The plunger heights must be measured and recorded. The plunger heights must be
measured to the nearest 0.25 of a millimetre.
10.4.3 If the lubricator has not used the amount of grease that is required for this lubricator since
the last time that it was maintained, check the following:
Check that the plunger heights are the same as when the lubricator was last maintained.
You may find that the plunger heights have changed due to loose bolts on the pump unit
bracket causing it to move, check the bolts and tighten if necessary. If necessary reset the
plunger heights once all the remaining checks have been carried out.
Note: The adjusting screws are designed for use and adjustment during initial installation only,
the adjusting screws include an anti-vibration feature to maintain the setting. Should further
adjustment be needed then the screw should be unwound to clear the pump body, oil / grease
contamination removed and Loctite 222 applied to the thread prior to re-fitting. Alternatively
new adjusting screws can be obtained, (see parts list LCS200-22).
If the plunger heights are lower than previously set but the bolts are all tight, check that the
plungers have not become flat, if so change them. Also the plungers may be stuck down due to
defective springs, this will be detected by the plunger operation test later in this Manual.