Whitmore LUBRICURVE ELECTRO 10 Instruction Manual

LUBRICURVE ELECTRO 10, 20, 30
Installation & Maintenance Manual
TRACKSIDE ELECTRIC RAIL & WHEEL LUBRICATOR
SYSTEM
Model Variants:
Solar (Mast) • Solar (Cabinet)
Solar & Wind • Mains
Battery • Control box MK3
90Kg, 200Kg, 400kg Capacity

2
Warning!
This lubricator uses a 12V-100Ah battery which contains a dilute sulfuric acid solution
known as electrolyte. Care must be taken to avoid the electrolyte coming in contact
with the skin or clothing as the electrolyte may cause severe burns.
If the electrolyte contacts the skin, wash with large quantities of clean water and seek
medical advice.
DO NOT expose the battery to naked flames or cigarettes
During the charging process hydrogen gasses are vented from the battery and these
gasses when mixed with the air may explode if ignited.
Do not short circuit the battery terminals, as this may cause a spark or explosion.

3
.Contents
1General 5
2Product Transport / Storage 5
3Main Component Definitions 6
4Preparation of Main Components for Installation 7
5Equipment Handling 8
6Typical Install Process 8
7Site Preparation 9
8Installation Trackside Items 12
8.1 Fitting the Trackside Cabinet to Mounting Base 12
8.2 Cabinet Door 13
8.3 Earth Bond 13
8.4 Lowering the Integral Lower Mast Unit 14
8.5 Option –Mast Removal / Alternative Lower Mast Orientation 14
8.6 Fitting the Upper Mast (wind turbine and / or solar power option) 15
8.7 Fitting the Solar Panel 15
8.8 Fitting the Wind Turbine 16
8.9 Raising the Integral Mast 17
8.10 Optional Mast Extension 18
8.11 Fitting of Cabinet Mounted Solar Panels 19
8.12 Battery Charger Electrical Connection 19
8.13 Solar & Wind Systems 20
8.14 Solar Systems - Mast Mounted 21
8.15 Solar Systems –Cabinet Mounted Panels 21
8.16 Mains Powered Systems 22
8.17 Battery Powered Systems 24
8.18 Replacing the Pump Sensor 24
9System Wiring Diagram 25
10 Installation of Track Items 26
10.1 Wheel sensor 26
10.2 Wheel sensor –Single Direction Operation 27
10.3 Blade System 29
10.4 Installing the Blade Rail Clamps (Standard Style) 29
10.5 Installing the Blades (Standard Style) 29
10.6 EasiBlade Installation 30
10.7 Outing of delivery hoses, Cabinet to blade 31
10.8 Fitting the Main Delivery Hoses 32
10.9 Fill the Hoses and Blade’s 33
11 Commissioning / Setting 34
11.1 Filling the Reservoir (Lid Lift Version) 34
11.2 Wheel sensor Heights and Operation 35
11.3 Pump Setting 35
11.4 Backlight & voltage display feature panel Error! Bookmark not defined.
11.5 Non backlight panel Error! Bookmark not defined.
11.6 Pump Settings / Operation 40
12 Routine Maintenance 41
12.1 Control Panel 41
12.2 Pump Setting 41

4
12.3 Measuring the Reservoir 42
12.4 Cabinet Maintenance 42
12.5 Battery Maintenance 42
12.6 Solar Panel Maintenance 43
12.7 Cleaning the Lubricator and Surrounding Site 43
12.8 Checking for Leaks 43
12.9 Measuring / Testing the Wheel sensor 44
12.10 Adjusting / Replacing Pump Sensor 44
12.11 Checking for Airlocks 45
12.12 Inspection of the Blade’s 45
12.13 Filling the Reservoir 46
12.14 Maintenance Frequency 46
12.15 Periodic Replacement of Components 46
12.16 Maintenance Log Sheet Example 47
13 Parts List 48
14 Basic Installation Tool Kit 48

5
1 General
Health & Safety legislation requires that rail lubricators are fitted by trained personnel only; warranty
will also be affected if un-trained teams work on the LubriCurve products.
Whitmore Rail provides suitable training courses.
This Manual should be used in support of training courses.
This Instruction Manual is intended to be generic and concentrates on the full range of LubriCurve
Electro 10/20/30 systems to suit flat bottom running rails; system install differences are highlighted
as necessary.
The lubricator uses a 12 Volt 115 Ah battery as a power source.
Only lubricator greases approved for use by Whitmore Rail and the rail user can be used in these
LubriCurve Electro systems. Use of other greases will invalidate warranty and could affect operation.
2 Product Transport / Storage
Goods are packed and delivered to the requested address in a form that is suitable for the product,
given good practice in the off-loading by the receiving company.
LubriCurve systems are delivered on the basis that they will be installed within one month of receipt.
Delivered systems are not intended for outside storage, equipment should be off loaded and stored
inside a secure watertight building until required for installation.
All items are carefully checked prior to despatch and any damage or missing parts should be advised
to Whitmore Rail within five days of despatch from Whitmore Rail premises.
Note:
Keep the cabinet upright at all times from transport to install

6
3 Main Component Definitions
Pump
Cabinet
Each trackside Cabinet contains: Reservoir, gear pump, gear pump hose, flow
adjusters, control panel, battery charger, reservoir filling valve, Cabinet mounting
brackets (fixed to the Cabinet).
The grease is delivered from the reservoir via the gear pump to the bulkhead hose
connectors on the external face of the Cabinet. Feed hoses then transfer grease to
the Blade system.
Pump
Reservoir
This reservoir holds the rail grease. The LubriCurve Electro 10 reservoir is capable of
holding 90Kg of grease, the Electro 20 –200kg and Electro 30 –400kg.
Pump
The pump unit consists of a twin chamber gear pump driven by a close-coupled 12v
DC motor. The unit fits directly to the reservoir underside.
Pump
Control
Triggered from the Wheel sensor the unit allows control of the pump and recording of
key data. A number of operational settings are user adjustable to suit the site and
application.
Wheel
Sensor
The wheel sensor clamps to the running rail and provides non-contact sensing of
passing wheels. Indicating lamps provide local indication of correct operation during
test. Sensor is connected to control box through armoured cable.
Integral
Mast
Generally integral with the Cabinet, the mast provides secure mounting of the solar
panel or wind turbine at a high level. Various heights and options are available.
Solar Panel
Depending on the model a solar panel is supplied. The unit fits onto the mast and is
used to provide power to the battery by utilising sun light and ambient light to
generate electric power.
Wind
Turbine
Depending on the model supplied a wind charger is supplied. The unit fits into the top
of the mast and is used to provide power to the battery in conjunction with the solar
panel.
Delivery
Hose
The delivery hose transfers the grease from the pump outlet to the Blade inlet.
Lengths of hose are supplied with each lubricator, which have to be cut into suitable
lengths to fit between the trackside Cabinet and Blade assemblies.
The hose is secured using a hose clip at each end of the hose.
Blade
(Grease
Dispensing
Unit - GDU)
Blades are provided 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. The quantity supplied is dependent on the application specified.
Each consists of three rectangular plates, back plate, middle plate and grooved front
plate (which has eight ports at the top of the grooved plate). Each Blade rail clamps
are suitable for the blade type.

7
4 Preparation of Main Components for Installation
Application
Ensure the correct pump type and system options have been selected for the
application.
Training
Ensure the installation team has been fully trained on the product, siting and
the application.
Packing
The Cabinet is delivered pallet mounted and wrapped, the Cabinet contains
the majority of loose items required for the install, and larger items are
secured to a separate pallet and wrapped.
Ensure the package has not been damaged during storage or transport to rail
site, damage must be reported to the equipment supplier on initial receipt.
Dispose of all waste packaging materials responsibly.
Cabinet
Visually inspect for any defects that will affect its operation.
Ensure that all loose items are available with reference to items ordered.
Ensure that the battery is fully charged with reference to the green indicator
lamp on the charge controller or the voltmeter display.
Blade
Ensure the blades are 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 Sensor 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 (feed and
delivery)
Ensure that the hoses are intact and free of holes and splits.
Wheel sensor & Cable
Ensure that the cable and sensor are intact and free of sharp kinks and any
kind of damage.
Serial Numbers
Lubricators are supplied with unique serial numbers; these should be recorded
prior to installation and recorded on installation record sheets as required.
Serial numbers are on both external and internal faces of the cabinet (door
hinge side)
Note:
Keep the cabinet upright at all times from transport to install

8
5 Equipment Handling
Generally Electro 10/20/30 items required for each site are delivered within the cabinet or attached
to it. The lubrication system is heavy and care should be taken in general, ensure safe mechanical
handling of the units from delivery truck off-load to site install (cabinet weight excluding grease is
over 100kg). There are three appropriate methods of handling the unit:
Fork Lift Truck. Lift with forks fully engaged under the cabinet.
Sling / Crane. The unit is designed to be lifted from the mast by attaching a suitable sling
around the ‘H’ frame. However the M12 fixings must be fitted through the mast
base plate to securely clamp the mast base to the cabinet prior to lift.
Personnel There are four carry points on the unit to suit the Whitmore Rail carry kit (Part
No. LCS105-01) and these should be used for all cabinet movements. The handle
should be passed through the corner angle-fixing hole and rotated vertically
through 90 degrees to secure. Four people are required, which should be trained
and experienced in mechanical handling. To reduce the overall weight, the
battery and other loose installation items that are shipped within the unit, should
be carefully removed prior to the lift and handled separately.
Note
The cabinet should be kept vertical at all times,
Take care to avoid damage to the paint finish as this forms part of the corrosion
resistance and general integrity of the unit.
6 Typical Install Process
There are several possible sequences that can be followed to efficiently install the lubricator, this will
largely depend on the personnel available, track access and general conditions –the following is
recommended as a guide.
Activity
Manual Section
1. Equipment Handling
5
2. Prepare Base for Cabinet Install
7, 8.1
3. Connecting the Power Source (solar, solar & wind, mains, battery)
8.4
4. Electrical Connection
8.12, 10.1
5. Install Blades
10.3
6. Install Track Mounted Wheel Sensor
10.1
7. Hose connection and routing from Blades to Cabinet
10.8
8. System Priming
10.9
9. System Settings
11

9
7 Site Preparation
To install a LubriCurve Electro 10/20/30 lubricator, a simple base is required to mount the Cabinet. The
form and stability of the base is important as it resists the wind loads on the solar panel and / or wind
charger. Typically the base would be formed from a pair of wood Sleepers / Ties suitably bedded into
ballast or surrounding ground. Alternatively a concrete plinth can be formed but that can be a costly
solution.
Systems with Masts
Outline and requirements are indicated in the diagram below. Recommendation is for two full length
(8’ 6”) good quality hardwood Sleepers / Ties to be fitted at 900to the track.
Where there is insufficient space in the CESS for that arrangement then two alternative options are
possible:
oTwo ¾ length (6’) sleepers can be used in place of the 8’ 6” standard, sleepers at 900to
the track. Sleepers must be ballast covered for adequate stability.
oTwo full length (8’ 6”) sleepers can be used. The sleepers must be parallel to the track and
spaced 0.95 metres (37”) apart. Sleepers must be ballast covered for adequate stability.
For any orientation described, sleepers are to be horizontal and level relative to each other and fully
bedded into ballast or secure ground.

10
The drawings below are applicable to the Electro 10 and Electro 20 systems.
640 nom'
1240
460
460 150 460
700 nom'
800 nom'
500 nom'
Direction of
Train Travel
View on arrow A
A
2897 3810
2150
2000
2100
2438 (8') nominal