Whitmore LUBRICURVE ELECTRO 5 Instruction Manual

LUBRICURVE ELECTRO 5
Installation & Maintenance Manual
TRACKSIDE ELECTRIC RAIL / WHEEL LUBRICATOR
SYSTEM
Running Rail
o2 blades
o4 blades
Top of Rail
o2 blades
o4 blades
35kg Capacity

2
Warning!
This lubricator uses a 12v-100ah battery which contains an acid based fluid, the
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 4
2Product Transport / Storage 4
3Main Component Definitions 5
4Preparation of Main Components for Installation 6
5Equipment Handling 7
6Typical Install Process 7
7Site Preparation 8
8Installation Trackside Items 10
8.1 Fitting the Trackside Cabinet to mounting tube 10
8.2 Fitting the Trackside Cabinet to Support Frame 10
8.3 Earth Bond 10
8.4 Fitting the Solar Panel 10
8.5 Battery Charger Electrical Connection 10
8.6 Solar Systems 11
8.7 Mains Powered Systems 12
9System Wiring Diagram 13
10 Installation of Track Items 14
10.1 Wheel Sensor 14
10.2 Blade System 15
10.3 EasiBlade Installation 15
Routing of delivery hoses, Cabinet to blade 16
10.4 Fitting the Main Delivery Hoses 16
10.5 Fill the Hoses and Blade’s 16
10.6 Top of Rail (TOR) EasiBlade Installation 17
11 Commissioning / Setting 18
11.1 Filling the Reservoir 18
11.2 Wheel Sensor Heights and Operation 18
11.3 Pump Setting 18
12 Routine Maintenance 22
12.1 Control Panel 22
12.2 Pump Setting 22
12.3 Measuring the Reservoir 23
12.4 Cabinet Maintenance 23
12.5 Battery Maintenance 23
12.6 Solar Panel Maintenance 24
12.7 Replacing the Pump Sensor 24
12.8 Cleaning the Lubricator and Surrounding Site 24
12.9 Checking for Leaks 25
12.10 Measuring / Testing the Wheel Sensor 25
12.11 Checking for Airlocks 26
12.12 Inspection of the Blade’s 26
12.13 Filling the Reservoir 26
12.14 Periodic Replacement of Components 27
12.15 Maintenance Log Sheet Example 28
13 Parts List 29
14 Basic Installation Tool Kit 29

4
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 5 systems to suit flat bottom running rails, both top of rail and gauge corner / face
applications; system install differences are highlighted as necessary.
Only lubricator greases or friction modifiers approved for use by Whitmore Rail and the rail user can
be used in these LubriCurve Electro systems. Use of other greases or friction modifiers 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 for consideration.
Note
Keep cabinet upright at all times from transport to install

5
3 Main Component Definitions
Pump
Cabinet
Each trackside Cabinet contains: Reservoir, gear pump, gear pump hose, control
panel, battery charger, and cabinet mounting brackets.
The grease is delivered from the reservoir via the gear pump to hose at the base of
the Cabinet. Feed hoses then transfer grease to the Blade system.
Pump
Reservoir
This reservoir holds the rail grease or friction modifier. The LubriCurve Electro 5
reservoir is capable of holding 35 Kg of grease or friction modifier.
Pump
The pump unit consists of a single or 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.
Solar Panel
Depending on model, a solar panel is supplied. The unit fits onto the rear of the
cabinet and is used to provide power to the battery by utilising sun and ambient light
to generate electric power.
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 that allows the grease or friction modifier to be delivered to the
gauge corner/gauge face or top of the rail, for the train wheels to pick up and spread
along the curve. The quantity supplied is dependent on the application specified.

6
4 Preparation of Main Components for Installation
Application
Ensure the correct pump type and system options have been selected for the
application.
Training
Ensure installation team has been fully trained on the product, sighting and
the application.
Packing
The Cabinet is delivered pallet mounted and wrapped, together with the
majority of loose items required for the install, and larger items are secured
to a separate pallet and wrapped.
Ensure 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 battery is fully charged with reference to green indicator lamp on
the charge controller or the voltmeter display.
Blade
Ensure they 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 and
cable
Ensure that the cable and sensor are intact and free of sharp kinks and any
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.

7
5 Equipment Handling
Generally Electro 5 items required for each site are delivered on a pallet. The lubrication system is
heavy and care should be taken in general safe mechanical handling of the units from delivery truck
off-load to site install (cabinet weight excluding grease is approximately 90kg). The following
methods of handling the unit are appropriate:
Fork Lift Truck. Lift with forks fully engaged under the cabinet.
Personnel Two people are required to lift the cabinet –Take care not to trap fingers or feet
when lowering to the ground.
The cabinet should be kept vertical at all times, take care to avoid damage to the paint finish as this
forms a 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 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. Electrical Connection
8.5, Error!
Reference
source not
found.
4. Install Blades
10.2
5. Install Track Mounted Wheel Sensor
Error! Reference
source not
found.
6. Hose connection and routing from Blades to Cabinet
10.4
7. System Priming
10.5
8. System Settings
11

8
7 Site Preparation
To install a LubriCurve Electro 5 lubricator, a simple base is required to support the vertical pole or the
rotational frame on which the Cabinet is mounted. The form and stability of the base is important as it
resists the wind loads on the cabinet. For a pole mount the base would typically be formed from
concrete with a 60mm diameter tube cast vertically. The tube is approximately 1000mm above the
concrete surface. For a rotational frame, the base could be either concrete or two full length sleepers.
Either construction the surface of the base must be flat.
Outline and requirements are indicated in the diagram below. Drawings are applicable to Electro 5 pole
& rotational frame mounting systems. Suitable poles and frames are available from Whitmore Rail.
B a sic S p e cif ic atio n .
S in g le cha m ber gea r pum p w ith 12 v
dc m otor
Inte rna l re servo ir a pp ro xim ay tley 1 2,5
K g c a pa city
12v d c o pera tion via 1 00 ah lead a cid
batte ry
110 /220 v M ain s cha rg in g o r 12 v dc
so lar pan e l ch a rging v ers io ns
W eig ht of c abin et (em p ty)
app ro xim atle y 95 kg
M o u nte d o n sin gle vertica l pole
app ro xim a tle y 3 50 m m a bov e g ro und
le vel
P ole fixed in con crete or bo lted to
sle epe rs b urie d in th e ba lla st.
120 0
350
Typ ica l insta llatio n - Po le m ounted
D C 3 1T
C o nt ro l
Blu e P o w e r 1 2/1 0
530 .00 28 0.0 0
885 .00
N o te !
Front o p enin g do or fo r
m ain te nance
& a cce ss to c ontrol
pan el
'X'
'X'
'Y'
'Y'
D C 3 1T
Mi dl a nd P u m p
Bir m in g ha m U K
N o te !
Top op enin g lid to fill
re se rv o ir w ith g re as e
N o te !
B a tt er y a c ce ss th ro u gh
front o p ening doo r
S e ctio n o n 'X -X '
V ie w o f F ro nt of C abin et
s ectio n on 'Y -Y'
N o te !
O p tio na l 36 w S ola r pa ne l
ca n b e m o u nte d on re ar of
ca b in e t a nd the c ab ine t ca n
be tu rn ed to give corre ct
orie ntatio n - T h e so la r pan el
to be us ed with ro tationa l
flo o r sta nd
V ie w o f R e ar o f C a bine t
Typ ical insta llatio n -
119 0.0 0
300 .00
R ota tio nal F lo or S ta nd
N o te !
S e ctio n s h ow n w it h
lu bric ato r m ou nted o n
a ve rtical p ole
(w ith op tio na l S olar pa nel)
N o te !
R e a r vie w s ho w n o n
rota tional floor stan d
Base and cabinet must be positioned to maintain mandatory track and OLE clearances.
Vegetation should be cleared around the unit where necessary to ensure a safe working
environment.
The base should be securely bedded into the ground / ballast to ensure stability and tube to be
vertical

9
The equipment needed for the installation work includes.
oAll relevant P.P.E. needed to carry out the works safely.
oShovel or ballast fork whichever one is the most suitable.
oOrange pipe to protect delivery hose and sensor cable across 4’ and 6‘.
oSpirit level
oCompass
oLubricator installation tool kit (see Section 14).
oWiring termination tools.
oCordless or portable drill and bits
Note. Other site specific mounting options may be used.

10
8 Installation Trackside Items
8.1 Fitting the Trackside Cabinet to mounting tube
8.1.1 The vertical tube is to be installed and the concrete is to be fully cured prior to the
installation of the cabinet
8.1.2 The Cabinet includes three clamps to hold the cabinet secure to the vertical tube. All
clamps are to be tightened at final fix.
8.1.3 The cabinet is positioned adjacent to the vertical tube and the three clamps are assembled
loose around the tube. The cabinet is then lifted approximately 300mm and the clamps are
tightened. Note if a solar panel is to be fixed to the rear of the cabinet, ensure the rear of
the cabinet is facing south for northern hemisphere and north for southern hemisphere
locations.
8.2 Fitting the Trackside Cabinet to Support Frame
8.2.1 The support frame is to be installed on a level firm base, either concrete or two full length
sleepers
8.2.2 The support frame is to be bolted to the concrete with M8 x 80 anchor bolts or M8 x 100
coach bolts, if timber sleepers are used.
8.2.3 The Electro 5P cabinet is bolted to the support frame with 4 No. M8 bolts fitted through
the base of the cabinet.
8.3 Earth Bond
8.3.1 Subject to local regulation it may be required to bond the unit to the track. A 16.5 mm
diameter hole is to be drilled in the rear of the cabinet for a 16mm diameter earth stud
(Whitmore Rail part No. LCS105-11).
8.3.2 The bond itself must be supplied and fitted directly by Rail owner authorised personnel
and not by the lubricator installer.
8.4 Fitting the Solar Panel
8.4.1 The solar panel is fixed directly to the rear of the cabinet. There are four spacers that hold
the solar panel away from the cabinet. Using the M8 security bolts attach the spacers to
the rear of the cabinet. The solar panel are fixed to the spacers with M8 security bolts.
8.4.2 The cable from the solar panel is routed through a 20mm gland to the inside of the cabinet
and the ends of the cable are connected to the solar panel controller.
8.5 Battery Charger Electrical Connection
The majority of the electrical termination is completed in the Whitmore Rail factory prior to
despatch, a maximum of three site connections (including one for the Wheel Sensor, Section
10.1.4) are required, for battery charging:
8.5.1 Solar Panel Cabinet Mounted –(see section 8.6)
8.5.2 Mains Power –two pole MCB for incoming 110 or 220vac fused and earthed mains power
(see section 8.7)

11
8.6 Solar Systems
Solar panel charged lubricator model uses the charger shown in
the picture. Cable connection is directly into the left hand side
screw terminals indicated on the charger.
The battery feed cable will have been factory connected, the free
end with ring terminals should be connected to the battery
terminals; blue core to negative and brown core to positive.
The round solar panel cable connects to terminals indicated with
the solar panel legend; Brown ‘+’, Blue ‘-‘
Damage will result if incorrectly connected.
The controller contains two indicator lamps:
A Green LED and this will be illuminated as soon as there is power from the module. When
the controller starts to limit the charge current the LED will flash.
The second LED can change colour from Red via Yellow to Green. Battery voltage is shown
by the colour and legend on the controller - Green full charge, Red low battery charge.
When the battery voltage falls below approximately 11v the multi colour LED will start to
flash FAST. While the battery remains at a low charge the LED will continue to flash slowly.
Warning!
This lubricator uses a 12v-115ah battery which contains an acid based fluid, the 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.

12
8.7 Mains Powered Systems
If solar charging is not possible an alternative system that utilises local mains power to maintain battery
charge may be used. Cable routing and connection should be undertaken by trained and authorised
personnel only. Using the following procedure:
8.7.1 A suitable cable should be routed from the local trackside power source to the cabinet via
suitable armoured cable and routed into the cabinet through a suitable waterproof gland.
The cabinet can be drilled towards the base to suit the gland; care should be taken to avoid
damage to any internal cabinet components.
8.7.2 The cable incoming cable should be armoured and suitably routed and protected to avoid a
hazard.
8.7.3 Cable rating should be 220/110 volt at 5 amps.
8.7.4 Connection should be made on the two pole MCBs to the left of the main Control Box. All
other power wiring will have been completed during product assembly.
8.7.5 Connection should only be undertaken with the lubricator installer present.
The mains charger is suitable for input voltage between 95 and 240 volts ac or dc.
The battery connections from the mains charger are:-
Cable with RED sleeve is connected to the positive battery terminal [Note: the cable insulation is
smooth]
Cable with no sleeve is connected to the negative battery terminal [Note: the cable insulation has
three longitudinal ribs]

13
9 System Wiring Diagram
Q H i
R ail
U K 0 15 2 5 6 22 202
w w w .q h ira il. co m
S e ria l N u m b er
W h ee l
D e te ct ed ON
P u m p In h i b ited P u m p
Less
M o re
W h e el s S te p s
W h e e l C o un t P u m p S t ep s
W h e el C o un t
T o ta l T o ta l
P u m p S t ep s
R u n
S to p
R u n
P u m p
1 0 S e c M A X
B a tte ry M o t or
P u ls e o /p
0 V W h M tr
W h ee l S e n se M o to r S e ns e
+ - + - - s + - s +
B A T T E R Y
G E AR B O X S EN S OR W H E E L S E N S O R
T R A C K M O U N T E D
BATTERY
S o ls u m 8 .8 c red
e m pt y
ye l lo w
gre en
fu ll
10
+ - + - + -
B A T TE R Y
3 6 W S O L A R P A N E L
S ola r P ow er
C ontrol P ane l
G ear P u m p
B ro w n c able from m o to r sp a de to
M o to r + t er m in a l in C o n tr ol B o x
B lue cable from m oto r sp a d e to
M otor - te rm in a l in C o ntro l B ox
G e a rb o x s h a ft tu rn s
c lo c k w is e fo r c o rre c t
p u m p o p e ra tio n
P ow er O ptions
1 2 v 1 0 a m p B a tt ery C h a rg e r
M a in s w irin g
by others
P lu g & M C B
s up p lie d w ith
Charger
W A R N IN G !
This lubric ator u ses a 12 v-100a h b a ttery w hic h conta ins an a c id b a sed flu id, the ele ctrolyte. C a re m u st be take n to a void th e ele ctro lyte
com ing in c onta ct w ith th e skin or clo th ing as th e ele c trolyte m a y ca u se se vere burns .
If th e ele c tro lyte conta c ts th e s kin , w ash w ith la rg e q uantities of clean w ater a n d see k m edical adv ise .
D O N O T e x pos e the b a tte ry t o na k e d fla m e s or c ig a re tte s
D u ring the ch a rg ing proce ss, hy drogen ga s se s a re vente d fro m th e b attery an d th e se ga s ses , whe n m ixed w ith the a ir, may e xplo de if
ig n ited. Do n ot sho rt c ircuit the b attery term in a ls, as th is m ay c a use a spark o r e xplo sio n.
E a rth C a ble 1 0 7-1 -8 8
M a in s S u pp ly
220 / 1 1 0v
50/60hZ
B y O th e rs
E L EC T R IC M O T O R
M a in s P ow er
N o te !
G e ar b ox s e ns o r n o t r eq u ire d i f
th e c o nt ro l b o x is " Pu m p T im e "
contro l
E le c tro 5 W irin g D ia g ram [118-2 -25 ]
Note –
Timed
version
control box
does not
have a
gearbox
sensor

14
10Installation of Track Items
This aspect of the installation involves fixing of the Wheel Sensor to the running rail, fixing of the
Blade system and running of the feed delivery hose system
10.1 Wheel Sensor
10.1.1 The Wheel Sensor is a non-contact proximity device that will detect a passing wheel when
correctly set. The unit is pre-assembled on an aluminium mounting plate and needs to be
clamped to the rail 3 to 6 metres upstream from the furthest rail mounted Blade. The
sensor will be in the 4’ and can be on either rail as best suited to the site.
Sensor rail fixing clamps are similar to the EasiBlade arrangement and fitting is generally covered
in Section10.3, key differences are:
Clamp the sensor to the M16 rail clamp studs with the sensor uppermost.
Adjust the height of the sensor to 42 / 45mm below the rail head crown and securely tighten the
M16 fixings.
Note if required by site conditions the sensor can be reversed on the sensor mounting plate such
that the cable exits in the opposite direction.
10.1.2 Run the cable from the sensor along the foot of the rail on the cess or field side, fix to each
rail clip using cable ties and into the trackside Cabinet through the lower mast pivot point
and into the cabinet.
10.1.3 The cable must route through protective pipe when running across the 4’ or 6’, in third rail
applications the cable should pass through robust insulated pipe work below the
conductor rail.
10.1.4 Route the cable within the Cabinet to the Control box. The sensor cable is armoured and
the ends will need to be prepared prior to connection.
10.1.5 Remove the two screw connector strip cover screws and route the sensor cable through
the cable gland and terminate all three cores as indicated
10.1.6 Cable connections are as follows:
Control Box: Wheel Sensor:
Brown: +ve terminal Brown terminal 1
Black: –ve terminal Black terminal 3
White: S terminal White terminal 4
Care should be taken to ensure connections are made correctly, that the terminals are not
over-tightened and damaged.
Note! On very small rails a simple plate with shims are used to mount the Wheel Sensor –see site specific
layout/ install drawings

15
10.2 Blade System
The system allows use of a range of grease distribution units:
Running Rail Blades
o2 blades on high rail
o4 blades on the high rail and 4 blades on the low rail
10.3 EasiBlade Installation
10.3.1 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.
10.3.2 Where 4 blades per rail systems are installed it is important that the two inner blades are
in adjacent beds an empty bed and then the outer blades. This arrangement allows wheel
circumference pick-up and also benefits hose layouts
10.3.3 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.
10.3.4 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.
10.3.5 Decide the required blade height and tap the two steel lugs on the blade evenly down
using a hammer to achieve the required height. The setting gauge should be used to verify
heights.
10.3.6 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.
Strike here to angle in blade
10.3.7 Repeat process for each EasiBlade.
Note!
Blade height should be set at approximately 6mm below the indicated wear
line on the gauge face of the rail. If no wear line is apparent a good starting point is 22mm below the top
of the rail

16
Routing of delivery hoses, Cabinet to blade
10.3.8 As outlined previously there are a number of options to
allow connection to the relevant Blade option. Picture
shows EasiBlade layout with empty bay between end
sleepers.
10.3.9 Hoses are 16mm bore for systems with pump distances
up to 8 metres. The correct type and length of hose will
have been despatched with the system.
10.3.10 Irrespective of hose type the principals of running the hose are similar and shown below
for a typical installation with blades on both rails.
10.3.11 Hoses should be protected within suitable piping when passing under rails across the 4’
10.3.12 Running Rail Systems
Two blades have single hose from cabinet to a T piece centrally between the two
blades.
Four blades have single hose from cabinet to a Y piece near each rail linked in turn to T
piece centrally between each blade pair.
10.3.13 Top of Rail Systems
Two blades have single hose from cabinet to a T piece centrally between the two
blades.
Four blades have single hose from cabinet to a Y piece near each rail linked in turn to T
piece centrally between each blade pair.
10.3.14 Specific hose routing will depend on each site, note, to assist balanced flow:
Main delivery hose runs should be of the same length.
Individual hose lengths between each interconnection should be the same length.
10.4 Fitting the Main Delivery Hoses
10.4.1 Having first filled the reservoir operate the pump by pressing the ‘run’ button until grease
is present at hose tail fitting.
10.4.2 Fit one end of a delivery hose to the hose tail inlet on the Blade with a hose clip and after
routing and filling the delivery hose connect to the hose tails on the outside of the pump.
10.4.3 Repeat the procedure for the other hose (If using a twin chamber pump with two hose
outlets).
10.5 Fill the Hoses and Blade’s
oThe main lubricator pump can be used to pump grease from the reservoir to the Blades.
oOn the Control Panel periodically press the Pump Run button.
oContinue cycle until grease is evident at all Blade ports.

17
10.6 Top of Rail (TOR) EasiBlade Installation
Process Applicable for Single Port TOR EasiBlade and 8 Port TOR EasiBlade
10.6.1 TOR EasiBlades are supplied as complete
single units. From the Field side and
midway between Sleepers / Ties slide the
base (W bracket) over the rail foot. 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.
[Single Port EasiBlade, above]
10.6.2 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.
10.6.3 Decide the required blade height and tap the two steel lugs on the blade evenly down
using a hammer to achieve the required height.
10.6.4 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.
10.6.5 Tighten the two M16 bolts. Adjust the nuts on the two lock bars to restrain the blade from
vibration.
10.6.6 Repeat process for each EasiBlade.
[Eight Port EasiBlade, above]

18
11Commissioning / Setting
11.1 Filling the Reservoir
The Electro 5 lubricators have been designed with a direct fill reservoir via a secure opening lid.
This direct fill method is the quickest and most user friendly filling method.
Access the Grease Reservoir
Open the lid on top of the cabinet. There are two latches (padlocks may be used to secure the
lid) that need to be released and the lid can then be hinged upwards. There is a stay in the lid
that prevent the lid from closing accidently. When the lid is open you will be able to see the
grease reservoir.
Note –ensure only approved grease or friction modifier enters the reservoir. Any non-approved
materials could severely damage the electric pump.
Filling the Grease Reservoir
Grease can be poured directly from the drum or
storage bag, into the reservoir. Electro 5
reservoir will hold 25 kg.
Do not over fill the reservoir.
Once filled close the lid by closing the lid slightly
then opening to release the lock and then the lid
can be closed fully. Press firmly shut and secure
using the latches. It is important that the lid is locked correctly; if the lid is left open the
grease / modifier may biodegrade rapidly.
11.2 Wheel Sensor Heights and Operation
Procedure for height adjustment and testing operation are covered in Section 12.10.
11.3 Pump Setting
The Electro 5 Lubricators are controlled and set by a control panel
located inside the cabinet. The control panel allows the user to set
the grease output from the Blade blades with respect to the rail
traffic using the line.
The following steps explain how to set and adjust the Lubricator
once installed.
The buttons and indicator lamps have been numbered to help
explain these instructions.

19
The first wheel of the train initiates the pump. The control panel counts the set number of wheels and
then operates the pump, grease / friction modifier is then dispensed every time the set number of
wheels has been detected.
The volume output is set in two ways depending on the application:
Running Rail
The control box pump setting can be either pump step or pump time variable [the control boxes
are different and the pump time variant is denoted by a “T” prefixing the serial number]. Set the
desired pump output by the number of steps or the run time in seconds.
Top of Rail
For TOR applications the control box is similar to the pump step version with a continuous train
operation and is identified by TOR prefixing the serial number. This type of control box does not
reset for individual trains.
All types of control panel look very similar and the method of setting the pump step and pump run time /
steps is similar.
11.3.1 Backlight & voltage display feature panel - Running Rail pump step type shown.
In order to access the control panel, open the main door of the cabinet
Ensure the control panel is switched on. Power button (1) must be pressed on the I rather
than the O. The controls are now sitting in a neutral state with the battery power allowing
basic function.
The Electro 5 Lubricators are activated by the Wheel Sensor ‘seeing’ the first wheels of a
train. When this occurs the Wheel Detected lamp (9) will illuminate as the sensor registers a
passing wheel. This situation can be replicated by passing a steel object over the sensor.
B a tte ry
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W he e l C o u n t P u m p S te p s
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B a tte ry M o to r W he e l S e n se M o to r S e nse
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UK 01582 622202
www.Whitmore
Railrail.com
NOTE!
All control boxes
look similar.
The Time Pump
version has “Pump
Sec” & “Sec”
adjacent to the
buttons 4&5 & “T”
prefixing the serial
number.
TOR version is the
same as the
running rail version
shown, but with
“TOR” prefixing the
serial number.

20
On detecting a wheel the electric pump will operate and the Pump ON lamp (10) will
illuminate. When the electric pump operates, grease will be despatched onto the rail through
the Blade blades.
The pump will run for the set number of steps or the set period of time. The higher the
number of steps or longer the pump runs for, the more grease will be despatched onto the
rail. 17 steps or 1.25 seconds equals one revolution of the pump gears.
The number of pump steps or pump seconds can be adjusted by pressing the Pump
steps/Seconds buttons, either (4) for More second or (5) for Less seconds. A usual setting for
Pump steps would be < 6 steps and for Pump seconds would be around <0.5 seconds
Once the pump has been activated the controller enters an inhibited period, and the Pump
Inhibited lamp (11) will be illuminated. The Wheel Sensor will continue to detect wheels but
will not operate the pump again until the set number of wheels has been detected.
The Wheel Count function controls the period between pump operations. To adjust the
Wheel Count press buttons (2) for More wheels to count or (3) for Less wheels to count. As a
train passes over the Wheel Sensor the number of wheels will be counted. When the number
of wheels reaches the set amount, the pump will be activated for the set number of Pump
Steps or pump seconds. Note –For Running Rail Applications - This inhibited period function
will reset after 45 seconds if the set number of wheels have not been counted. This means
the pump will be ready to go every time a new train passes over the Wheel Sensor. For TOR
Applications –There is no resetting of the inhibited period therefore the TOR control box
carries the wheel count settings from one train to the next.
To more easily view the display panel press backlight button (12), the light will automatically
extinguish after a set time.
Central to the display is a battery voltage read-out; this is disabled while the pump is running.
Variation for TOR operation:
The Electro 5 is active once the control panel is switched on. The pump is activated every time the
control panel counts the set number of wheels. The wheel count may be split between two trains.
Typical Settings
Setting the wheel count and pump seconds is accomplished as described in section above
11.3.2 The required pump settings will vary for each site and depend on such items and train type
and speed. For guidance the tables below should be followed and then adjustments made
to suit local conditions during subsequent visits.
Initial Electro 5 Settings –Running Rail - Pump Time
Speed
Carriages
Carriages
Carriages
2
3
4
Speed
mph
Speed
kph
Wheel
Count
Pump
Secs
Wheel
Count
Pump
Secs
Wheel
Count
Pump
Secs
<15
<25
3
0.3
3
0.3
4
0.4
<50
<80
3
0.3
3
0.3
4
0.4
<75
<120
3
0.3
4
0.3
6
0.4
<100
<160
3
0.3
4
0.3
6
0.4
<125
<200
-
-
-
-
-
-