MC SERIES MECHANICAL WAYSIDE LUBRICATION … · mc series mechanical wayside lubrication system installation & maintenance manual service & parts 415 holiday drive pittsburgh, pa

MC SERIES MECHANICAL WAYSIDE LUBRICATION SYSTEM

INSTALLATION & MAINTENANCE MANUALSERVICE & PARTS

415 Holiday Drive Pittsburgh, PA 15220Phone: 412.928.3400Fax: 412.928.3510Email: [email protected]

172 Boul. BrunswickPointe-Claire, Quebec H9R5P9 Canada Phone: +1 514.695.8500 x236Fax: +1 514.695.8110Email: [email protected]

TABLE OF CONTENTSIntroduction ...................................................................................................................................................................................................................1Applications ...................................................................................................................................................................................................................1Installation ......................................................................................................................................................................................................................2Placement of Tank ........................................................................................................................................................................................................2Ramp Assembly Installation .....................................................................................................................................................................................3Ramp Adjustment ........................................................................................................................................................................................................3MC-3 and MC-4 .............................................................................................................................................................................................................4MC-3 Manifold Assembly with Grease Trough ...................................................................................................................................................6MC-3 Manifold Assembly without Grease Trough ............................................................................................................................................7MC-3 Parts Illustration ................................................................................................................................................................................................8MC-3 ..................................................................................................................................................................................................................................9MC-4 ..................................................................................................................................................................................................................................9MC-4 Wiping Bar Installation and Maintenance ............................................................................................................................................. 10MC-4 Wiping Bar Assembly w/Trough & Clamps ........................................................................................................................................... 11MC-4 Wiping Bar Manifold Assembly ................................................................................................................................................................. 12MC-4 Wiping Bar Assembly without Trough, with Clamps ......................................................................................................................... 13MC-4 Wiping Bar Manifold Assembly ................................................................................................................................................................. 14Hose Connections ..................................................................................................................................................................................................... 15Tank Positioning ........................................................................................................................................................................................................ 15Universal ....................................................................................................................................................................................................................... 15Final Steps .................................................................................................................................................................................................................... 16Operation ..................................................................................................................................................................................................................... 16Maintenance ............................................................................................................................................................................................................... 16Troubleshooting ........................................................................................................................................................................................................ 17Service ........................................................................................................................................................................................................................... 18Changing Key Location ........................................................................................................................................................................................... 19Servicing Pump Assembly...................................................................................................................................................................................... 19Typical MC-3 One Bar Installation ....................................................................................................................................................................... 20Typical MC-3 Two Bar Installation ........................................................................................................................................................................ 21Typical MC-3 Four Bar Installation ....................................................................................................................................................................... 223-Way Valve Assembly Operation ........................................................................................................................................................................ 234-Way Valve Assembly Operation ........................................................................................................................................................................ 24Typical MC-4 Two Bar Installation ........................................................................................................................................................................ 25Typical MC-4 Four Bar Installation ....................................................................................................................................................................... 26Tank Assembly and Universal ............................................................................................................................................................................... 28Ramp Assembly and Miscellaneous Hardware ............................................................................................................................................... 29CATCH-ALL Track Mat ............................................................................................................................................................................................... 31MatMate - BarTender ................................................................................................................................................................................................ 31Additional Products .................................................................................................................................................................................................. 32

Page 1

IntroductionThe MC Series rail and flange lubricators are designed for optimum performance under all traffic conditions.

The MC Series lubricator prolongs the life of the rail and wheel flanges by as much as 50 percent to 400 percent by delivering grease at the proper height through multiple discharge ports. Passing wheel flanges activate the ramp lever, pick up the grease and distribute it to the gauge face of the rail, greatly reducing friction between the rail and the wheel flange.

When properly installed and maintained, the MC Series lubricator is one of the most effective ways to protect both rail and wheel flanges. This manual is designed to help you properly install and maintain an MC lubricator.

ApplicationsOne Rail-Two BarDesigned for use in any area to protect one rail only. Generally used in areas of continuous curvature, where heavy grades prevail and where it is found to be more economical to calculate the protection of each rail separately. Also used in yard areas where curvature is in one direction only.

Two Rail-Two BarDesigned for use on mainline to protect both rails where isolated or continuous reverse curvature exists. For use on grades not over one percent. Also for use in yards for switching in both directions and for switch point protection.

Two Rail-Four BarDesigned for use in the same areas as the standard lubricator with two bars, but where additional coverage is desired. The two bars on each rail serve to provide the equivalent grease distribution of two standard two bar lubricators. This model is for use in tangent track or in areas of continuous curvature where the grades are not over one percent. For grades over one percent, consult your L.B. Foster representative.

Page 2

InstallationGeneral LocationThis lubricator is made for installation in either tangent track or curve spirals. When the lubricator is to be installed in single direction track, it should be installed in the tangent track, or in the beginning of the spiral of the first curve that is to be lubricated. When it is to be installed in track that has traffic in both directions, the lubricator can be placed in the tangent between two curves. Excellent results have been achieved when the lubricator is installed in the spiral of the curve where the super-elevation is approximately ½”.

Tools RequiredPick, shovel, maul, claw hammer, 14” adjustable wrench, 14” pipe wrench, combination box/open end wrenches, 6” adjustable wrench.

Advance PreparationFor better utilization of on-track time, the tank hole can be dug beforehand.

Placement of TankExcavate a hole, as shown, that will locate the front of the tank approximately 25” from the railhead. The hole should be deep enough so that the top of the tank will be level with the top of the railhead. Set the tank in the hole. Do not backfill until the ramp assembly and universal are installed and connected.

Note: Oversize and rectangular tanks should be installed 28” from the railhead.

Page 3

Ramp Assembly Installation1. Insert ¾” diameter set screws into the threaded blocks

located at either end of the ramp assembly until the screws extend approximately 1” below the blocks. These screws allow ramp assembly to be raised or lowered.

2. Place the slotted ramp clamps on the bolts located next to the threaded blocks, and finger tighten with lockwasher and nut. Be sure there is a flat washer between the ramp clamp and the lockwasher.

3. Place the ramp assembly with clamps on the rail base at the position marked, as shown on drawing. Use a winged spacer between each clamp and the top of the rail base. These spacers are used to protect the rail from any scratches or gouges.

4. Put the J-bolts through the ramp clamps, hooking the bolt on the gauge side of the rail base.

5. Fully tighten ramp clamps to the rail base. The ramp assembly should be free to move up and down in the slotted ramp clamps. If the ramp assembly binds against the railhead, insert another winged spacer between the rail base and ramp clamps.

Ramp AdjustmentInsert “U” shaped spacers behind ramp clamps until the ramp is as close as possible to the railhead without actually touching. If a lip is present on the field side of the railhead, it should be ground off, as shown at left.

Turn the square heads set screws up or down so that the top of the ramp, in its highest position, is approximately 1/8” above the top of the rail. Keep the ramp assembly level with the rail. Tighten the nuts on the ramp clamps and double check the ramp height above the rail, snug up the square head set screws and tighten the cross bolts to lock the set screws in position. For increased grease flow, the ramp lever may be raised as high as 3/8” above the top of the rail.

Page 4

MC-3 and MC-4Grease Distribution SystemsThis section contains detailed information on the MC-3 and MC-4 wiping bars installation and maintenance, as well as, arrangements of the popular two-bar and four-bar distribution system configurations. All L.B. Foster lubricators can be adapted to use any L.B. Foster, or competitive distribution system.

This manual addresses the most popular configurations.

It should also be noted that we highly recommend the use of the MC-3 or MC-4 wiping bar in the vast majority of installations as they directly replace the MC-2 and are much simpler to install then the MC model. The MC-2 wiping bar and associated part are no longer available so it is recommended that they be upgrade to MC-4 bars.

A. Installation & Maintenance - MC-3® Grease Distribution Wiping Bars

1. The MC-3 grease distribution wiping bar can be mounted in a curve and/or to worn rail provided the rail has at least 3/8” of gauge face that is not being contacted by the wheel flange in addition to the normal tangent track and does not need to be ground into the rail. First, lay the wiping bar on the gauge side of the rail at the approximate desired location to gauge the location of the rail clamps. When two or more bars are installed, the bars should be spaced approximately 45”-50”, center-to-center of each bar, with at least one tie between them. This insures lubrication of opposing wheel quadrants for maximum grease coverage.

2. Hook the two rail clamps onto the rail base aligned with the slotted pockets on the wiping bar by sliding the clamp hook first from the gauge side under the rail until the hook can be raised to engage the rail.

3. Lift and hold wiping bar “manifold radius” TIGHT up against underside of railhead (see FIGURE 3). While holding bar up tight, lower manifold set screws towards rail base. Rotate wiping bar out at the

bottom as shown on the following page. Snug set screws to secure wiping bar up tight to railhead. IMPORTANT: These vertical manifold set screws are NOT height adjustment screws for the distribution blades. (Blade height adjustment instructions follows.) Manifold radius must be positioned tightly to railhead to prevent bar from loosening and falling off.

4. Swing rail clamp up tight up to the rail base in line with receiving slotted pockets in wiping bar assembly. Choose shortest clamp screw to provide maximum wheel flange clearance and place in the appropriate hole to allow the highest approach to the receiving slot. The higher slot engagement is best for wiping bar securement. Snug clamp screws to wiping bar, lightly tapping the head of the set screw to seat cup point into the wiping bar.

5. Return to wiping bar vertical set screws and tighten securely, fully wedging wiping bar manifold radius “tightly” into the railhead. Tighten the rail clamp set screws, lightly tapping the rail clamp onto the rail.

6. Tighten all jam nuts securely.

MC-3 Wiping Bar Maintenance

Occasionally it may be necessary to disassemble and clean your wiping bars due to damage or clogging of ports. Use of any typical cleaning solvent is acceptable. However, NEVER USE A WIRE BRUSH OR ABRASIVE WIPE ON PORT SURFACES OF BAR AS THAT WILL DAMAGE THE NON-STICK COATING. A soft bristle brush may be used provided it does not scratch the coating. Heating of the bar to melt hardened grease is acceptable providing the heat is not concentrated for long periods to the point where the bar turns red.

Page 5

NOTE 2

NOTE 4

NOTE 5

NOTE 3

NOTE 1

7/8" TO 1-1/8"FROM TOP OF RAIL

132 RE RAIL

109

MINIMUM GAGEFACE WHICH DOESNOT SEE WHEELFLANGE CONTACT

3/8

MC-3

Figure 3

Notes:1. Manifold radius to be held securely to railhead by vertical

setscrews (#109) to prevent bar loosening.

2. Maintain contact at these two points while adjusting vertical setscrews (#109) down.

3. Rotate bottom of bar out toward edge of rail base as shown above.

4. Setscrews must be tightened securely to assure the fit between wiping bar and fishing area of rail.

5. Select shortest clamp screw which works the best for rail size and hole in clamp to allow the highest approach to the slot in the manifold assembly. As the clamp screw is tightened, it should tend to pull clamp up tight against underside of rail base. If clamp appears to walk down away from rail base as it is tightened, remove clamp and rotate bottom of bar out more as stated in Step 3. Use jam nut to lock screw in place.

MC-3 Wiping Bar - Blade Set Height Adjustment

General Note: In order for wiping bar assemblies to mount properly, there must exist at least a 3/8” high area on the gauge face on the rail where wheel flanges do not contact. If the railhead is worn to a point where there is not at least

3/8” of gauge face available, move the wiping bars to the next closest place which will properly lubricate the area.

1. All wiping bar assemblies are assembled with blade set adjusted to the fully-lowered position. For most installations, the wiping blades will have to be raised according to the procedure outlined in Steps 2 through 5 that follows.

2. The blade height is recommended to be no closer than 7/8” from top of rail to minimize wheel contact. This distance as assembled may need changed with various applications to different rail sizes, head wear and gauge face wear.

3. To adjust, first loosen (8) hex head capscrews #115 located under the lip of the back bar/grease trough approximately 1 to 1 ½ turns, using 3/16” Allen wrench.

4. With a flat screwdriver, the blade can be adjusted up or down (while the wiping bar is mounted to the rail) up to 3/8” by gently bumping each end of the blade set upward or downwards. The blade can be elevated by prying up at the tail piece at each end of the blade set if it is bumped too low. Re-tighten the eight socket head capscrews.

5. A distance of 7/8” to 11/8” below top of rail is recommended but more is allowable if conditions permit the wheel flange to pick the grease up. Higher settings may allow the blade set to be pinched by the wheel flange. In general, adjust blade set only high enough for wheel flange to pick up grease. If any marking appears along edge of grease distributing blade, this is a sign that the blade is set too close to top of rail and should be adjusted down to prevent the grease ports from being pinched shut.

103 104

105

3/8" ADJUSTMENT ITEM #103 & #104 TOGETHER

115

Page 6

MC-3 Manifold Assembly with Grease Trough

101

103 104

105106

107 115

109

112

113

102

116

Item # Part # Number Required Consists of Description

788-07001-50 1 MC-3 Wiping Bar Assembly Complete w/Clamps 80/140#

40 788-07002-50 2 Rail Clamp Assembly Complete w/Hardware

41 700-650-050 1 ½” UNC Jam Nut

42 700-702-250 1 ½” UNC x 2½” Square Head Set Screw Cup Point


788-07000-50 1 MC-3 Manifold Assembly Standard 80# - 140# Rail

101 788-07003-50 1 Manifold Sub-Assembly

102 788-00003-00 1 Grease Blade Set (consists of #103 and #104)

103 788-01002-00 1 Front Blade

104 788-01003-00 1 Distribution Blade

105 788-01004-00 1 Back Bar Grease Trough

106 701-000-075 1 ¾” Standard Elbow 90°

107 700-621-075 4 ¼” INC x ¾” Socket Head Cap Screw GR.8

109 788-01020-00 2 ¾” UNC x 3½” Hex Socket Set Screw Cup PT

112 700-650-076 2 ¾” UNC Jam Nut

113 968-00026-74 1 ¾” x 2” Pipe Nipple

115 700-560-125 8 ¼” UNC x 1¼” Hex Head Cap Screw GR.8

116 700-675-025 8 ¼” Standard Lockwasher Medium

114 952-00025-71 1 Hose Adapter Pipe to Straight (sold separately)

Page 7

MC-3 Manifold Assembly without Grease Trough

101

112

107113

109

104103

116

106117

115

102

Item # Part # Number Required Consists of Description

788-07001-52 1 MC-3 Wiping Bar Assembly Complete w/Clamps 80/140#

40 788-07002-50 2 Rail Clamp Assembly Complete w/Hardware

41 700-650-050 1 ½” UNC Jam Nut



788-07007-50 1 MC-3 Manifold Assembly Standard 80# - 140# Rail (w/o Grease Trough)

101 788-07003-50 1 Manifold Sub-Assembly

102 788-00003-00 1 Grease Blade Set (consists of #103 and #104)

103 788-01002-00 1 Front Blade

104 788-01003-00 1 Distribution Blade

106 701-000-075 1 ¾” Standard Elbow 90°

107 700-621-075 4 ¼” INC x ¾” Socket Head Cap Screw GR.8

109 788-01020-00 2 ¾” UNC x 3½” Hex Socket Set Screw Cup PT

112 700-650-076 2 ¾” UNC Jam Nut

113 968-00026-74 1 ¾” x 2” Pipe Nipple

115 700-560-125 8 ¼” UNC x 1¼” Hex Head Cap Screw GR.8


117 788-01078-00 2 Back Bar

114 952-00025-71 1 Hose Adapter Pipe to Straight (sold separately)

Page 8

MC-3 Parts Illustration

43

42

40

41

101

102

103104

105106

115

113

114

106

104 GREASE PORTS

BLADE ADJUSTMENT SLOT OF 9/16" TOTAL

116

Page 9

Features MC-3 MC-4Patented grease port design Yes Yes

Number of grease ports 18 18

Manifold with patented streamline grease channels Yes Yes

Patented Teflon® coating on grease channels* Yes Yes

Wear resistant distribution blade with V-grooves and Teflon® coating* Yes Yes

Optional grease trough Yes Yes

Common wrench size between mounting and grease hoses No Yes

Rail base block mounting system utilizing J-bolt No Yes

Patented elevating screw mounting system with universal rail clamp Yes No

No-grind design Yes Yes

Mounting in curves Yes Yes

Mounting to head-worn rail Yes Yes

Guard rail applicable Yes Yes

Cleanable manifold* Yes Yes

Specifications

Weight 23 lbs 23 lbs

Length

Mounting 233/8” 241/8”

Blade 22¾” 22¾”

Overall 263/8” 26½”

Blade adjustment 3/8” ¾”

Wheel coverage per bar

28” diameter 26% 26%



40” diameter (locomotive) 18% 18%

Rail sizes (others available upon request) 85-140 lb 112-140 lb

*Note: Never use a wire brush or abrasive wipe when cleaning.

MC-3

MC-4

Page 10

MC-4 Wiping Bar Installation and MaintenancePlease refer to the assembly drawing C788-07009-00 as needed.1. It is strongly suggested the MC-4 Wiping Bar is

mounted in tangent track (on virtually any worn rail condition.) The wiping bar DOES NOT need to be ground into the rail. First, lay the wiping bar on the gauge side of the rail at the approximately desired location to establish the location of the clamping system. When two bars are to be installed on each rail, the bars should be placed 45”-50” center-to-center. This insures lubrication of opposing quadrants of the wheel for maximum grease coverage.

Refer to the drawing on page 12.1. Slide the clamp blocks (ITEM 2) onto the rail base

below the horizontally slotted holes in each of the manifold (ITEM 1). Hook the J-bolts (ITEM 3) on the field side of the rail base and through the holes in the clamp blocks. Install lockwashers (ITEM 6) and hex nuts (ITEM 7) loosely on J-bolts.

2. Install spacers (ITEM 7) and flatwashers (ITEM 8) on top of clamp blocks as needed to achieve a 7/8” to 11/8” distance from the top of rail running surface to the tip of distribution blade on ITEM 1. We recommend initially setting the blade height at 11/8” and watching the first train passage to observe the grease transfer from rail to wheel. The correct setting will vary depending on typical wheel conditions of flange height and hollow tread. Watch for evidence of the wheel flange touching the distribution blade and lower accordingly.

3. When an initial height setting is established, tighten all fasteners using appropriate hand tools. The manifold should be held in tight against gauge face of the rail. Under no circumstances should a gap exist between blades and gauge face of the rail.Please refer to the bill of material on the drawing attached to order any replacement parts.

Note: Occasionally it may be necessary to disassemble and clean your wiping bars due to damage or clogging ports. Use of any typical cleaning solvent is acceptable. However, NEVER USE A WIRE BRUSH OR ABRASIVE WIPE ON PORT SURFACES OF BAR AS THAT WILL DAMAGE THE NON-STICK COATING. A soft bristle brush may be used provided it does not scratch the coating. Heating of the bar to melt hardened grease is acceptable providing the heat is not concentrated for long periods to the point where the bar turns red.

Page 11

MC-4 Wiping Bar Assembly w/Trough & ClampsDrawing C-788-07016-00

Item # Part # Number Required Description

788-07016-50 1 MC-4 Wiping Bar Assembly with Trough and Clamps

1 D788-07015-50 1 MC-4 Wiping Bar Manifold Assembly with Trough

2 B788-01079-00 2 Mounting Clamp

3 A900-031-272 2 J-Bolt

4 A788-01081-00 4 3/8” Spacer

5 N700-528-250 2 Hex Head Cap Screw GR.5¾” UNC x 2½”

6 N700-675-075 4 ¾” Lockwasher

7 N700-641-075 2 ¾” UNC Hex Nut

8 N700-694-075 8 ¾” USS Hardened Flat Washer GR.8

9 N700-660-075 2 ¾” Elastic Lock Nut

10 N956-00025-81 2 Open End Spacer (B900 025 810)

11 A775-56312-32 2 Keyed Hardened Flat Washer

12 N778-07012-50 2 Rail Clamp Sub-assembly (includes Items 2 through 11)

3

3

7/8" TO 1-1/8"

6" RAIL BASE

131, 132 RE RAIL

133 RE RAIL

3/16

1/4(136 RE SHOWN)

3

136, 140 RE RAIL

AND TOWARD GUSSET

ASSEMBLE WITHLIP IN UP POSITION

5-1/2" RAIL BASE

3

2

6

2 67

9

4 8 10 *

7/8" TO 1-1/8"

(115 RE SHOWN)112, 115 RE RAIL

3/16

AND TOWARD GUSSET


79

104 8 *

6

1315

11

1

119 RE RAIL

13

116

5

1

*Shim as needed so that wiping bar is between 7/8” and 1-1/8” below top of rail.

Page 12

MC-4 Wiping Bar Manifold AssemblyDrawing D-788-07015-00


788-07015-50 1 MC-4 Wiping Bar Assembly Standard 112#-140#

1 D788-01080-00 1 Manifold

2 D788-01001-00 1 Manifold Port Side

3 D788-01002-00 1 Front Blade

4 D788-01003-00 1 Distribution Blade

5 D788-01004-00 1 Back Bar

6 N700-675-025 8 ¼” Standard Lockwasher Medium

7 N700-621-075 4 ¼” UNC SK HD CPS GR.8

8 N700-560-125 8 ¼” UNC Hex HD CPS GR.8

(SEE EXPLODED VIEW)

STANDARD ASSEMBLY3 4

A

86

5

A

EXPLODED VIEW(ASSEMBLE LEFT TO RIGHT)

1

1

4

4

17

2

86

2

8

TO RIGHT AS SHOWN. TAB LOCKSFIND NO. 4 WHEN ASSEMBLED.

ASSEMBLE FIND NO. 3 WITH TAB

6

3 45

VIEW A-A

1

2 4

5

86

3

TIGHTEN ELBOW TO 4 O’CLOCK POSITION

ASSEMBLE WITH BLADE SET & TO THE HIGHEST POSITION

Page 13

MC-4 Wiping Bar Assembly without Trough, with ClampsDrawing C-788-07009-00


788-07009-50 1 MC-4 Wiping Bar Assembly without Trough, with Clamps

1 D788-07010-50 1 MC-4 Wiping Bar Manifold Assembly

2 B788-01079-00 2 Mounting Clamp3 A900-031-272 2 J-Bolt

4 A788-01081-00 4 3/8” Spacer

5 N700-528-250 2 Hex Head Cap Screw GR.5¾” UNC x 2½”

6 N700-675-075 4 ¾” Lockwasher

7 N700-641-075 2 ¾” UNC Hex Nut

8 N700-694-075 8 ¾” USS Hardened Flat Washer GR.8

9 N700-660-075 2 ¾” Elastic Lock Nut

10 N956-00025-81 2 Open End Spacer (B900 025 810)

11 A775-56312-32 2 Keyed Hardened Flat Washer

12 N778-07012-50 2 Rail Clamp Sub-assembly (includes Items 2 through 11)

136, 140 RE RAIL

131, 132 RE RAIL

133 RE RAIL

119 RE RAIL112, 115 RE RAIL(115 RE SHOWN)

(136 RE SHOWN)

1 5

6

8

4

2

6 7

35

6

8

2 6

3

4

1

7

11

11

*10

*10


AND TOWARD GUSSET

AND TOWARD GUSSETLIP IN UP POSITIONASSEMBLE WITH

5-1/2" RAIL BASE

6" RAIL BASE

1/4

3/16

3/16

7/8" TO 1-1/8"

7/8" TO 1-1/8"

*Shim as needed so that wiping bar is between 7/8” and 1-1/8” below top of rail.

Page 14

MC-4 Wiping Bar Manifold AssemblyDrawing D-788-07010-00


788-07010-50 1 MC-4 Wiping Bar Assembly Standard 112#-140#

1 D788-01080-00 1 Manifold

2 D788 01001-00 1 Manifold Port Side

3 D788-01002-00 1 Front Blade

4 D788-01003-00 1 Distribution Blade


7 700-621-075 4 ¼” UNC SK HD CPS GR.8

8 700-560-125 8 ¼” UNC Hex HD CPS GR.8

9 B788-01078-00 2 Back Bar

VIEW A-A

TIGHTEN ELBOW TO 4 O’CLOCK POSITION

ASSEMBLE FIND NO. 3 WITH TAB TO RIGHT AS SHOWN. TAB LOCKS FIND NO. 4 WHEN ASSEMBLED.

SEE EXPLODED VIEW

EXPLODED VIEW(ASSEMBLE LEFT TO RIGHT)

STANDARD ASSEMBLY3 4ASSEMBLE WITH BLADE SET & TO THE HIGHEST POSITION

Page 15

Hose ConnectionsRemove protective caps from grease connections in tank and wiping bars and:

1. Connect male end of long hose to grease outlet in tank.

2. Connect male end of 34” hoses to grease inlet on wiping bars.

3. Assemble hose adapters to the three-way cock.4. Check and tighten all connections.5. Connect hoses to the adapters on the three-way cock

and tighten.6. Secure hoses to the ties with the hose straps provided.

Note: Two bar lubricator may be installed as single rail or double rail lubricator. See Page 1 for layout.

Hose arrangements are shown on Pages 20, 21, 22, 25 and 26.

Tank PositioningPosition the tank and backfill the hole so that the front of the round tank is 25” from the railhead and the closed lid is even with the top of the railhead. The universal should be reasonably straight if the tank is located properly. Extreme misalignment will cause excessive wear on the universal shaft.

Universal1. Make certain that universal yokes are in line and that

any locking device located on the telescoping part of the universal is loose enough to allow free extension.

2. Apply grease to the splined shafts on the ramp lever and tank.

3. Connect one end of universal to ramp lever shaft.4. Rotate until the ramp lever is in its highest position

and connect the other end of the universal to the splined shaft extending from the grease tank.

5. Extend the universal as far as possible and lock the universal at the desired length. Locking device may be other than as shown.

Page 16

Conventional method (left) of filling wayside lubricator vs bulk fill (right).

Operation1. Check Rail

The lubricator may be operating perfectly, but its actual performance can only be determined by inspecting the rail down line after a week or so of operation. There should be a grease film on the gauge face and corner of the rail throughout the curve.

The amount of protection to be expected is usually calculated before the lubricator installation is made. For advice or assistance, contact Customer Service at 412.928.3400

2. Excessive GreaseIf grease is on top of the rail three or more rail lengths beyond the lubricator, the ramp and/or wiping bars should be lowered.

3. Insufficient GreaseIf grease is not evident on the gauge face of the rail throughout the curve and the lubricator is functioning mechanically, the ramp and/or distributing bars should be raised.

Final Steps1. Fill tank to just below rocker arm with proper lubricant.

Use puddling bar to make sure there are no air bubbles.

2. Operate the pump mechanism manually by rocking the universal until grease flows evenly from all discharge ports in the wiping bars. The pump is self-priming. Note: The relief valve inside the tank is preset at the factory to protect against a ruptured hose in the event there is a blockage somewhere in the system. DO NOT CHANGE THE SETTING TO ADJUST GREASE FLOW.

3. Check all nuts, bolts and fittings for tightness. Coat some grease on nuts and bolts to protect against corrosion.

4. Grease Alemite fittings on ramp assembly and universal joints. (See maintenance instructions regarding importance of greasing these fittings regularly.)

L.B. Foster Rail Technologies offers bulk transfer system for easier and faster grease filling.

MaintenanceL.B. FOSTER RAIL TECHNOLOGIES LUBRICATORS SHOULD BE INSPECTED AND SERVICED AT REGULAR INTERVALS TO PROVIDE MAXIMUM EFFICIENCY WITH MINIMUM UPKEEP.

Grease FittingsThere are three fittings on the universal assembly and one grease fitting on the ramp assembly that require periodic lubrication. Regular lubrication will greatly decrease wear on the splined shafts and yokes.

Page 17

TroubleshootingIf no grease appears at the outlet ports, the cause of the problem will be in one of three areas:

1. Ramp Lever, Universal and Pump Shafta. Check for wear at the point where the wheels strike

the ramp lever. Adjust or replace ramp as necessary.

b. There should be very little play between these parts. If the ramp cannot be raised any higher, the worn parts should be replaced. Note: Temporary adjustment can be made to raise the ramp. Refer to Changing Key Location on page 19.

2. Pumpa. Check the pump push rod and rocker arm for proper

engagement.

b. Check pump by rocking universal shaft.

c. If grease is returned to tank through relief valve, the pump is operating properly. Note: If the lubricator does not have a relief valve in the tank, DO NOT continue pumping. Disconnect hose at nearest convenient point and check for grease output.

d. If no grease appears anywhere in the system, the pump must be repaired, or if necessary, replaced.

3. Distributing Barsa. If grease is being pumped back into the tank through

the relief valve, the wiping bars are plugged and should be cleaned or replaced.

b. Make certain all fittings are tight. Replace hoses if deterioration is evident.

c. In the event of a burst or vandalized hose, shut off the grease flow at the three-way cock until a replacement can be made.

RampWear on the ramp will necessitate periodic adjustment to keep the ramp 1/8” above the top surface of the rail. Refer to Page 16 for adjustment of ramp assembly. If unable to position ramp lever, change key location on pump lever shaft assembly.

Drive AssemblyWear on the splined shafts and yokes will cause excessive play in the drive assembly. This slack action should be taken up by changing the key location. Rotating the universal 1, 2 or 3 splines and reassembling will have a similar effect. However, in no case should the ramp lever strike the stop on the ramp frame when in the ready position. With proper assembly, the pump lever should always rest against the stop bracket on the pump support crossbar when in ready position.

Wiping BarsDirt, caked-on grease and possible wheel flange contact may cause the outlet ports to clog. Solvent and a stiff brush should be used to keep the bars clean. It may be necessary to use a wire periodically to unclog an outlet, depending on type of grease used. However, on MC-3 and MC-4 wiping bars NEVER USE A WIRE BRUSH OR ABRASIVE WIPE ON PORT SURFACES OF BAR AS THAT WILL DAMAGE THE NON-STICK COATING. A soft bristle brush may be used provided it does not scratch the coating. Heating of the bar to melt hardened grease is acceptable providing the heat is not concentrated for long periods to the point where the bar turns red.

FillingMake certain enough grease is in tank to cover the pump and prevent air intake. Use “puddling bar” (inside tank) to stir grease before and after filling to make sure there are no air bubbles, especially in cold weather. Pump is self-priming.

Jam NutsAll jam nuts should be checked for tightness.

BoltsAll bolts, nuts, clamps and hose fittings should be checked for tightness.

Page 18

ServiceMC-3 service - see page 4MC-4 service - see page 10

Universal Drive Shaft - Removal and Replacement1. Loosen locking device on universal so that universal

shaft is free to telescope.

2. Remove universal one end at a time.

3. Replace universal by engaging ramp end first.

4. Rotate until ramp is in its highest position and engage the tank shaft.

5. Extend universal as far as possible and tighten locking device.

6. Apply grease to Alemite fittings.

Ramp Lever - Removal and Replacement1. Remove universal.

2. Remove the two nuts closest to center of the ramp assembly.

3. Remove ramp and ramp frame.

4. Replace ramp.

5. Replace ramp frame assembly. Tighten nuts.

6. Reinstall universal.

7. Apply grease to Alemite fittings.

8. Readjust ramp to proper height (see page 16).

Pump Shaft – Removal and Replacement1. Remove universal.

2. Loosen bolt on rocker arm and slide towards rear of tank until it clears stop.

3. Remove key from keyway in shaft. Note: Wipe excess grease from pump shaft until the letter “T”, “H” or “L” (stamped on the shaft next to the keyway) is visible. When replacing key in new pump shaft, it will have to be put into the same “T”, “H” or “L” keyway that it was in on the old pump shaft.

4. Remove push rod and check overall length; it should be 17¾”.

5. Loosen set screws in collars until the collars move freely on shaft.

6. Remove pump shaft from front of tank.

7. Install new pump shaft, placing collars and rocker arm on shaft.

8. Replace key in proper keyway, install push rod by engaging both ends and slide rocker arm over key until the rocker arm is in position and forced up against the stop.

9. With the collars against the front and rear shaft bushings, tighten set screws. Note that there are flat spots on the pump shaft for the set screws.

10. Reinstall universal.

Page 19

Changing Key Location(Recommended when parts become worn.)

1. Remove universal from pump shaft.2. Loosen bolt on rocker arm and slide towards rear of

tank until it clears stop.3. Remove key from keyway in pump shaft.4. Rotate shaft and replace key in next keyway.5. Return rocker arm to its original position and tighten

bolt.6. Replace universal on pump shaft. Note: It may be

necessary to repeat this procedure if the shaft ends are still not in alignment while the ramp is in its highest position.

7. Adjust ramp lever to correct operating height.

Servicing Pump AssemblyPump Removal1. Loosen nut on rocker arm and slide towards rear of

tank.2. Remove pump rod.3. Disconnect hose at upper end.4. Remove two cap screws holding crossbar in place.5. Pull crossbar upwards until it clears guide rod.

Pump Disassembly1. Remove cap on bottom of pump.2. Remove spring and ball check through bottom of

pump.3. Lift out pump piston and spring through top of

pump.4. Remove pump body from bracket.5. Clean all parts thoroughly with solvent, including

inlet screens.6. Check for free movement between piston and pump

body (without spring). If necessary, smooth bottom of piston and inside diameters of the bushings in the pump body with emery cloth. If piston still binds, or action is not smooth, they should be replaced.

7. Replace top or bottom spring if weak, short or broken.

8. Proper length of top spring is 3³/16”.9. Proper length of bottom spring is 2”.10. Reassemble pump body to bracket.11. Reassemble pump.

Pump Support Bracket Installation1. Replace in tank by placing hole in pump bracket over

guide rod.2. Attach crossbar to brackets.3. Connect hose.4. Replace pump push rod.5. Return rocker arm to original position and tighten.

Be sure key is in place.

Hoses1. When replacing hose, make sure the hose lengths

from tank to the wiping bar are the same.2. Connect all hoses male end first.3. Tighten all connections securely.

Page 20

Typical MC-3 One Bar InstallationOne bar on one rail shown using MC-3 wiping bar and clamps, although the same configuration is used for all style wiping bars.

FROM TANKGREASE HOSE

3

2

3

4

9

Item # Part # Number Required Description788-00017-00 1 MC-3 1-Bar and Hose Retro-fit Kit

2 788-07000-50 1 MC-3 Wiping Bar Manifold Assembly3 788-07002-50 2 MC-3 Rail Clamp Assembly4 902-00021-76 1 Hose ¾” x 34” Long9 967-00026-73 1 ¾” Standard Coupling

Page 21

Typical MC-3 Two Bar InstallationOne bar on each rail or two bars on same rail. Shown using MC-3 wiping bars and clamps, although the same configuration is used for all style wiping bars.


2 788-07000-50 2 MC-3 Wiping Bar Manifold Assembly3 788-07002-50 4 MC-3 Rail Clamp Assembly4 902-00021-76 2 Hose ¾” x 34” Long5 951-00025-61 1 ¾” 3-way Valve Assembly

3

2

3

4

NORMAL USE

BE IN LINE WITHHANDLES SHOULD

VALVES FOR

5


OPTIONAL LOCATION

4

2

3

3

Page 22

Typical MC-3 Four Bar Installation



GREASE HOSEFROM TANK

5

4

4

2

3

3

2

3

3

HANDLES SHOULDBE IN LINE WITHVALVES FORNORMAL USE

2

3

3

4

4 3

2

3

Page 23

3-Way Valve Assembly OperationL.B. Foster Rail Technologies Part #951-00025-61

3/4" PIPE TEE (GALVANIZED)

3/4" PIPE NIPPLEUSED ONLY ON 4-BARDISTRIBUTION SYSTEMS

GREASEOUTLET

HANDLE IN THIS POSITIONBLOCKS FLOW THRU VALVE

GREASEINLET

GREASEOUTLET

SCREWS INTO 3/4" TEE

3/4" ONE WAY VALVEMALE END OF VALVE

HANDLE IN THIS POSITION ALLOWS FULL FLOW THRU VALVE

Notes:1. Handles may be removed at discretion of maintainer.2. Refer to specific distribution system being used to determine if ¾” pipe nipple is needed for your installation.

Page 24

4-Way Valve Assembly OperationL.B. Foster Rail Technologies Part #788-30007-08

Notes:1. Handles may be removed at discretion of maintainer.2. Pipe tees and pipe nipples are galvanized.

3/4" PIPE TEE

GREASEOUTLET

HANDLE IN THIS POSITIONBLOCKS FLOW THRU VALVE

GREASEINLET

ALLOWS FULL FLOW THRU VALVEHANDLE IN THIS POSITION

SCREWS INTO 3/4" TEE

3/4" ONE WAY VALVEMALE END OF VALVE

3/4" PIPE TEE

3/4" PIPE TEE

OUTLETGREASE

GREASEOUTLET

OUTLETGREASE

3/4" X 8" PIPE NIPPLE

3/4" X 8" PIPE NIPPLE

Page 25

Typical MC-4 Two Bar InstallationOne bar on each rail or two bars on same rail. Shown using MC-4 wiping bars and clamps, although the same configuration is used for all style wiping bars.

Item # Part # Number Required Description788-00026-00 1 MC-4 2-Bar and Hose Kit


NORMAL USEVALVES FORBE IN LINE WITHHANDLES SHOULD

3

3

2

3

3

2

4

OPTIONAL LOCATION

4

5


Page 26

Typical MC-4 Four Bar Installation

Item # Part # Number Required Description788-00021-00 1 MC-4 4-Bar and Hose Kit


3


3

5

3

2

3

2

4 4 3

4 4

2 2

3

3 3

HANDLES SHOULD BE IN LINE WITH VALVES FOR NORMAL USE

Page 27

Page 28

Tank Assembly and UniversalDescription Part Number RequiredComplete Round Tank + Pump Assembly 735-00021-01 1[Round Tank w/Large Pump Assembly] 970-00027-10 -[Large Tank w/Standard Pump Assembly] 976-00028-00 -[Large Tank w/Large Pump Assembly] 979-00029-10 -Round Tank w/Lid [42 Gallon] 736-00021-14 1[Large Tank w/o Lid (75 Gallon)] 977-00028-10 - Tank Bushing 905-00021-13 2Pump Support Bracket Assembly 906-00021-20 1Cap Screw ½” x 1½” w/LW + Nut 907-00021-21 2Cap Screw ⁵/8” x 2” w/LW + Nut 908-00021-22 2Pump Screen 918-00021-47 1Round Tank Lid Assembly 734-00021-32 1[Square Tank Lid Assembly] 909-00021-30 -[Large Tank Lid Assembly] 806-00028-30 - Cover Hinge Bolt w/Nut 910-00021-31 1Standard Pump Assembly 911-00021-40 1[Large Pump Assembly] 971-00027-40 - Standard Pump Body 817-00021-41 1[Large Pump Body] 808-00027-41 - Pump Bushing– Lower 865-00017-42 1 Retaining Pin 866-00017-44 1 Pump Piston Spring 913-00021-42 1 Standard Pump Piston 914-00021-43 1[Large Pump Piston] 972-00027-43 - Standard Ball Valve 915-00021-44 1[Large Ball Valve] 973-00027-44 - Ball Valve Spring 916-00021-45 1 Ball Valve Spring Seat 917-00021-46 1 Pump Screen 918-00021-47 1 Pump Gasket 912-00021-48 1Pump Lever Assembly 919-00021-50 1 Bolt ½” x 3¾” w/Nut 920-00021-51 1Pump Lever Shaft Assembly 922-00021-60 1 Collar w/Set Screw 923-00021-61 2 Set Screw 921-00021-63 1 Key ³/8” x ³/8” x 1⁵/8” 803-00021-62 1Pump Rod 17¾” 897-00021-71 1Extension Piece ¾” 898-00021-72 1Flat Washer 1” 899-00021-73 2Relief Valve w/Bushing 901-00021-74 1Pipe Tee ¾” 900-00021-75 1Hose 34” 902-00021-76 1Pudding Bar 903-00021-77 1Hose Adapter 952-00025-71 1Complete Universal Assembly 946-00024-00 1Hose Clamp 900-02411-0 -Hose Spacer 900-02412-0 -Grease Fitting 1/8” Standard 946-00023-21 -Grease Fitting 1/8” 60 Degree 946-00024-21 –

Page 29

Ramp Assembly and Miscellaneous HardwareDescription Part Number RequiredComplete Ramp Assembly 812-xxx23-00 1Ramp Lever 939-00023-01 1Ramp Backing Bar Assembly 940-xxx23-10 1Bolt ½” x 2” w/LW + Nut 941-00023-11 2Rib Neck Bolt ¾” x 3½” w/LW, FW + Nut 943-00023-12 4Set Screw ¾” 942-xxx23-xx 2Ramp Frame Assembly 944-00023-20 1Grease Fitting 1/8” Standard 945-00023-21 1Ramp Clamp High Standard 824-02625-31 -Ramp Clamp low 823-13225-32 -Ramp Clamp High Special - 150# - 175# 822-00425-33 -Ramp Clamp Low Special - 70# - 75# 821-22825-34 -Ramp Clamp 122CB Rail Special 820-05625-35 -SPECIFY RAIL SECTION WHEN ORDERING PARTS LISTED ABOVEHose 19½” 962-00026-02 -Hose 34” 902-00021-76 -Hose 52” 953-00025-51 -Hose 68” 758-68255-30 -Hose 94” 885-00018-03 -Hose 240” 758-51255-40 -J-Bolt 1” x 11” w/LW + Nut 778-05252-15 2J-Bolt 1” x 11” w/ESNA Nut 778-06252-25 -Cone Insert 790-00211-48 -Conversion Kit [Add 2 No-Grind Bars] 792-x0204-5x -Conversion Kit [Add 2 Grind-In Bars] 802-xxx20-40 -Clamp Shim [Winged Spacer] 805-00025-92 -One Way Ramp Assembly 894-00023-60 -Pipe Tee ¾” (package of 10) 900-00121-75 -Standard Elbow ¾” x 90 (package of 10) 934-00122-31 -Bolt 1” x 11’ w/LW + Nut 950-00025-21 -Open End Spacer (package of 10) 956-10025-81 -Pipe Strap w/Nails (package of 10) 963-10026-03 -Street Elbow ¾” x 90 (package of 10) 934-00122-39 -Pipe Nipple ¾” x 4 966-00026-72 -Pipe Coupling ¾” 967-00026-73 -Pipe Nipple ¾” x 3” 968-00026-74 -Ramp Backing Bar Assembly, ESNA Nuts 983-xxx23-40 -Gauge Side Clamp, ESNA Nuts 985-xxx25-15 -Bolt 1” x 11”, ESNA Nuts 987-00025-22 -Shut Off Valve ¾” 988-00029-28 -

(xxx) Indicates rail size is needed

Page 30

Page 31

CATCH-ALL Track MatSoil and Ballast Protector

Functions as a “high-tech carpet” by covering the lubrication site ground surface, yet permitting water to pass through. Placed over the ties, it is easily and quickly cut to match any gauge face or top-of-rail applicator configuration. Excess lubricant that would have otherwise penetrated the soil or ballast is easily removed from the CATCH-ALL Track Mat surface (when in place) or can be disposed of by removing and replacing the unit entirely. CATCH-ALL has excellent durability and is highly resistant to ultraviolet deterioration, solvents, puncture, excessive temperatures, moisture and high volume traffic. CATCH-ALL Track Mat is the standard of many Class I railroads and transit systems and is available for different gauges by request.

MatMate - BarTenderGrease that collects around rail-mounted applicators at lubrication sites is not only an environmental concern but also a nuisance to those responsible for the maintenance of these applicators. Grease accumulation is more concentrated at the rail mounted applicators than anywhere else at the site. In order to keep sites cleaner and safer L.B. Foster Rail Technologies has developed the MatMate - BarTender to facilitate easy collection and disposal of excess grease around applicators at sites utilizing CATCH-ALL Track Mats. The MatMate is a supplemental device for lubrication sites that use CATCH-ALL Track Mats and is not intended as a stand-alone appliance. It fits standard and extended length applicator bars and is disposable as well as light weight. In addition to improving safety and “housekeeping” at lubrication sites the MatMate - BarTender may enhance the life of CATCH-ALL Track Mats in applications where the common practice is to remove heavily soiled mats.

CATCH-ALL Track Mat shown with MatMate - BarTender grease collection pan.

U.S. CUSTOMER SUPPORT

L.B. Foster Rail Technologies Inc.415 Holiday DrivePittsburgh, PA 15220412.928.3400

CANADA CUSTOMER SUPPORT

L.B. Foster Rail Technologies (Canada) Ltd.172 Brunswick BoulevardPointe-Claire, QC H9R 5P9514.695.8500

UK & EUROPE CUSTOMER SUPPORT

L.B. Foster Rail Technologies (UK) LimitedStamford StreetSheffield S9 2TL, UK S92KS+44(0)114.256 2225

TECHNICAL INQUIRIES

L.B. Foster Rail Technologies Corp.4041 Remi PlaceBurnaby, BC V5A 4J8 CanadaToll-Free North America: 800.653.9210Outside North America 1.604.415-3000

Additional Products• 761 Hydraulube Hydraulic Wayside Lubricator

• CATCH-ALL Track Mat Soil & Ballast Protector

• PROTECTOR® IV Electronic Top-of-Rail & Gauge Face Friction Management Systems

• Guard Rail Lubricator

• Retrofit Kits

• Bulk Transfer Systems

• High Speed Rail Tribometer

• KELTRACK® Friction Modifier

• Rail Curve Grease

www.lbfoster.com

Documents

MC SERIES MECHANICAL WAYSIDE LUBRICATION … · mc series mechanical wayside lubrication system installation & maintenance manual service & parts 415 holiday drive pittsburgh, pa