Viper Mid MKII Assembly & Operation Manual

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VIPER MID MK II WIRE ROPE

LUBRICATOR

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Contents

1.0 Introduction ................................................................................................... 4

1.1 Key features of the Viper Mid MKII WRL include: ................................... 4

2.0 Included Kit Components............................................................................. 5

3.0 Viper Mid MKII Kits Components Assembled & Numbered ...................... 6

3.1 Viper Mid MKII Standard Kits ................................................................... 6

3.1.2 Viper Mid MKII Standard Complete Hose .......................................... 7

3.1.3 Viper Mid MKII Standard 20KG Kit .................................................... 8

3.1.4 Viper Mid MKII Standard 20KG Pump Kit .......................................... 9

3.1.5 Viper Mid MKII Standard 50KG Kit .................................................. 10

3.1.6 Viper Mid MKII Standard 50KG Pump Kit ........................................ 11

3.1.7 Viper Mid MKII Standard 180KG Kit................................................. 12

3.1.8 Viper Mid MKII Standard 180KG Pump Kit ...................................... 13

3.1.9 Viper Mid MKII Standard 180KG Hose............................................. 14

3.2 Viper MKII High Speed Kits .................................................................... 15

3.2.1 Viper Mid MKII HS Complete Collar ................................................. 15

3.2.2 Viper Mid MKII HS Complete Hose .................................................. 16

3.2.3 Viper Mid MKII HS Complete 20KG Kit ............................................ 17

3.2.4 Viper Mid MKII HS Complete 20KG Pump Kit ................................. 18

3.2.5 Viper Mid MKII HS Complete 50KG Kit……………………………….19

3.2.6 Viper Mid MKII HS Complete 50KG Pump Kit ................................. 20

3.2.7 Viper Mid MKII HS Complete 180KG Kit .......................................... 21

3.2.8 Viper Mid MKII HS Complete 180KG Pump Kit ............................... 22

3.2.9 Viper Mid MKII HS Complete 180KG Hose ...................................... 23

4.0 Viper Mid MKII WRL Assembly Instructions ............................................. 24

5.0 Ratchet Strap Buckle Assemblies - Ref: AW107 ...................................... 27

6.0 Viper Mid MKII WRL Operating Instructions ............................................. 28

7.0 Lubricant Penetration ................................................................................. 30

8.0 Equipment Specifications .......................................................................... 31

9.0 Trouble Shooting ........................................................................................ 32

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10.0 Safety Recommendations – Caution Level Rating ................................. 33

11.0 Danger Rating ........................................................................................... 34

12.0 Viper Mid MKII Guarantee......................................................................... 35

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1.0 Introduction

The VIPER Mid MKII Wire Rope Lubricator is an Australian designed and built
lubricator for wire rope sizes from 6mm (1/4”) to 36mm to 67mm (2-5/8”). It
provides fast and effective single pass lubrication of wire ropes, eliminating the
slow and arduous task of manual lubrication. Lubrication of wire ropes with the
Viper system provides superior protection against corrosion and fretting wear by
forcing lubricant into the core of the wire rope while also coating the outer
strands. The use of the Viper WRL MKII improves operator safety and reduces
the environmental impact of wire rope lubrication for any size operation.

1.1 Ke y features of the Viper Mid MKII WRL include:

1. Viper collar constructed from high grade aluminium with a high visibility
corrosion resistant coating.

2. New Viper collar is 32% lighter than the original Viper unit and
incorporates cast carry handles for easier handling.

3. Unique polyurethane seal design provides largest pressure contact area to
ensure maximum lubricant pen etr ati o n.

4. Durable and wear resistant polyurethane seals last thousands of meters in
normal service.

5. Seal and scraper size range to cater for rope sizes 6mm to 67mm.

6. High pressure high flow 45:1 grease pump delivers lubricant at up to 4.5kg
per minute and pressures up to 5,500 psi.

7. Global distribution net work which provides local customer support.

Viper Mid MKII collar with unique built in handles

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2.0 Included Kit Component s

1. Viper Mid lubricator collar, cast aluminium with inbuilt handles, includes

lubricant delivery line quick connect coupling and excess lubricant fit ti ng .

2. High pressure high flow customized Viper 45:1 grease pump to suit 20kg
50kg/180kg drum sizes which comes preassembled with:

a. Air control valve
b. Air regulator with gauge
c. High pressure grease flow control valve
d. Male quick connect fitting

3. Four (4) metre, high pressure, ½” hydraulic hose complete with female

quick connect couplings on each end.

4. One (1) metre clear hose for excess lu bri c ant di sc har g e.

5. Two (2) x 2 metre ratchet straps rated to 500kg.

6. Four (4) x “Bow” shackles.

7. Viper collar shoulder carry strap.

8. Heavy duty al umini um stor ag e case with stainless steel fixtures.

9. Polyurethane seals & Aluminium Scraper plates (ordered separately)

a. Sized to suit specific size ropes - 6mm / 4/16” to 67mm / 2-5/8”
b. Please reference the Seal & Scraper Selection Guide

10. Viper Wire Cleaners (optional accessory)

a. Available to suit a variety of ropes – refer to Viper selection guide.

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3.0 Viper Mid MKII Kits Components Assemble d & Num be red

3.1 Viper Mid MKII Standard Kits

3.1.1 Viper Mid MKII Complete Standard Collar

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3.1.2 Viper Mid MKII Complete Standard Hose (included in 20KG & 50KG

kits)

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3.1.3 Viper Mid MKII Complete 20KG Kit

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3.1.4 Viper Mid MKII Complete 20KG Pump Kit

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3.1.5 Viper Mid MKII Complete 50KG Kit

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3.1.6 Viper Mid MKII Complete 50KG Pump Kit

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3.1.7 Viper Mid MKII Complete 180KG Kit

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3.1.8 Viper Mid MKII Complete 180KG Pump Kit

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3.1.9 Viper Mid MKII Complete 180KG Hose

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3.2 Viper MKII High Speed Kits

3.2.1 Viper Mid MKII Complete HS Collar

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3.2.2 Viper Mid MKII Complete HS Hose (included in 20KG & 50KG kits)

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3.2.3 Viper Mid MKII Complete HS 20KG Kit

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3.2.4 Viper Mid MKII Complete HS 20KG Pump Kit

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3.2.5 Viper Mid MKII Complete HS 50KG Kit

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3.2.6 Viper Mid MKII Complete HS 50KG Pump Kit

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3.2.7 Viper Mid MKII Complete HS 180KG Kit

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3.2.8 Viper Mid MKII Complete HS 180KG Pump Kit

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3.2.9 Viper Mid MKII Complete HS 180KG Hose

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4.0 Viper Mid MKII WRL Assembly Instructions (refer assembly video on website)

1. Remove all components from Viper Mid aluminium carry case,

unpack from packing materials and lay out on a flat surface. Check
all items are present as per your purchase order.

2. Remove grease pump noting that the air inl et i sol ati on val ve,
air regulator and high-pressure needle control valve are
preassembled onto the pump.

• Connect site specific compress ed air connector to
the air regulator. (not supplied)

3. Remove lid from lubricant container and place follower plate
onto the top of the lubricant. Press down firmly until the
follower plate comes in contact with the lubricant.

• Note the Viper Mid lubricator should only be used with
high quality wire rope lubricants with a consistency of
NLGI#00 to 2.

4. Fit the drum cover over the top of the lubricant container and
tighten the three securing screws until they contact the
container.

5. Clamp the grease pump handle onto the grease pump body and
tighten the two screws.

6. Slide the grease pump shaft into the opening of the drum cover
and the follower plate. Push the grease pump down into the
grease until it touches the base of the gr eas e cont ainer.

7. Connect the high-pressure grease hose to the grease pump
outlet via the quick connect coupling.

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8. Remove the Viper Mid collar from the packaging materials and
loosen the two clamping bolts allowing the collar to open.

9. Fit the scraper plates to the Viper Mid collar using the counter
sunk screws and the Allen key provided. Note scraper plates
are sized to suit the wire rope as per the “Seal & Scraper plate
selection guide”.

10. Fit the Viper seals into the Viper Mid collar. Make certain that
the grease inlet holes on the seal and viper collar are aligned.
Note seals are sized to suit the wire rope as per the “Seal &
Scraper plate selection guide”.

11. Clamp the lubricator collar fitted with seals and scrapers around
the wire rope to be lubricated, tightening the two toggles.

• Face the collar so that the hydraulic coupling is at the
rope inlet end when the rope is being moved through
the collar.

• Locate the collar so that the optimum length of wire
rope can be lubricated in a single pass, this is typically
close to the winch drum.

12. Attach the clear plastic drain hose to the Viper Mid collar. This
hose is to deliver exces s lubr i cant bac k t o a collection container.

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13. Connect the high-pressure lubricant delivery hose to
the Viper Mid Collar using the quick connect coupler.

• Standard Kit

• High Speed Kit

14. To secure the Viper Mid lubricator collar in place, use the nylon
ratchet straps and ‘Bow’ shackles.

• Secure one end of the ratchet strap to one of the lugs on the
wire entry end of the lubricator collar via a bow shackle.
Secure the other end to a suitable fixed position to prevent the
lubricator collar from travelling with the wire rope. Replicate
this using the second ratchet strap, bow shackle and lug on
the lubricator collar.

• Note the ratchet strap is in high tension and strain during
operation. Please ensure that all fittings are tightly secured
prior to operation.

• The lubricator collar must be able to move laterally during
operation to ensure even wire rope spooling on and off the
rope drum.

15. Connect the air supply to the air regulator unit fitted to the grease
pump. Ensure that the air shut-off valve is off, preventing the air from
reaching the pump motor. Set the air pressure regulator to 7 bar.

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5.0 Ratchet Strap Buckle Assemblies - Ref: AW107

Basic Steps of Operation

To Tighten:

1. Secure Hooks on either side of load.

2. Insert free end of strap through slot A and pull through excess webbing

3. Push down and pull up handle B to work the ratchet strap till strap is as tight as possible.
a. Do not over tighten, as the straps are only designed to maintain position of the Viper

Collar.

4. Ensure at least 2 to 3 revolutions of webbing are around centre cam A.

5. Push Handle B down to lock your Tie-Down.

To Release:

1. Pull back on quick release C and hold.

2. Pull handle B up and over to a fully open flat position.

3. Pull tie-down up to loosen strap and remove from slot A.

To be used as a guide only
Please note: Lubricate all moving parts on a regular basis.

Use and Care Instructions – Webbing Load Restraint Systems Ref: AW116
Use: The selected lashing system should be both strong enough and of the correct length for the mode of

use. Good lashing practice should always be followed; the fitting and removal operations of the lashing
should be planned before starting a journey. The lashing should be suitably
Pre-tensioned and regularly checked.

CAUTION: NOT TO BE USED FOR LIFTING

INSPECTION: Web lashings and any fittings or coupling components attached should be subject of frequent

visual inspection and regular examination by a competent person. Web lashings shall be withdrawn from
service if there is cause to doubt fitness for use.

MARKING: Use only legibly marked and labelled web lashing.
OVERLOADING: Lashing systems should not be overloaded. Mechanical aids such as levers or bars
should not be used unless they are specifically designed for use with the device.
PROTECTION: The webbing and labels should be protected against friction, abrasion and damage from

load with edge radii less than twice the webbing material thickness, using protective sleeves or corner
protectors.
SERVICEABILITY: Normal wear and tear can reduce the strength of the webbing assemblies. If webbing is
damaged by more than 10% of its original state due to abrasion, cuts, prolonged exposure to sunlight or
chemicals then it should be replaced. Similar, if tensioning devices such as hand ratchets and end fittings
are damaged by wear or corrosion they should be replaced.
RESPONSIBILITY: It is the responsibility of the owner, the driver and the person in charge of the loading to
ensure that a vehicle’s load restraint and attachments, and the load securing equipment, are serviceable
and strong enough for their application.
NOTE: The user of this strap assumes all risk and liability for its handling and use.

For further information please refer to the RTA ‘Load Restraint Guide’.

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6.0 Viper Mid MKII WRL Operating Instructions

With the Viper Mid Wire Rope Lubricator assembled and mounted correctly as
per the previous instructions, you are now ready to operate the system and
lubricate the nominated wire rope.

1. Make sure the high-pressure lubricant flow control valve is closed (turn

clock wise to close).

2. Open the air supply to the lubricant pump via the air control valve. The

pump may start to pump for a short period but will stop as the lubricant
reaches the closed lubricant flow control valve. Check that the air regulator
is set to 7 bar. (100psi)

3. Open the high pressure lubricant flow control valve slowly by turning anti

clockwise and proceed to fill the installed seal with lubricant. Once
lubricant appears at the wire rope entry point or in the overflow drain line,
close the lubrica nt fl ow control valve by turning clockwise.

THE VIPER IS NOW CHARGED AND READY FOR OPERATION.

4. Start the wire rope moving through the Viper Mid collar and then slowly

open the lubricant flow control valve. Continue to open until an even
coating of grease is visible on the wire rope exiting the collar.

• Speeds of up to 2,000 metres per hour are possible but this

depends on a number of factors, including the rope size, speed and
specific lubricant in use.

5. The lubricant flow control valve should be adjusted as required to provide

the correct lubricant flow rate into the lubricator collar and thereby onto
and into the wire rope.

• If the lubricant flow rate is too high lubricant will begin leaking out of

the Viper Mid collar at the rope entry point or from the excess
lubricant clear hose.

• Reduce the lubricant flow by turning the flow control valve

clockwise. Alternatively increase the wire rope speed through the
lubricator collar until the correct amount of lubricant appears on the
wire rope.

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Unlubricated wire rope

Lubricated wire rope

6. Visually inspect the wire rope as it exits the collar to observe if full

lubricant coverage is being achieved.

• If insufficient coverage is being achieved, increase lubricant flow
rate by adjusting the lubricant metering valve anti clockwise until
an even coating is occurs.

• Alternatively reduce the rope speed until an even lubricant
coating occurs.

7. If lubricant leakage occurs around the collar, check the collar is correctly
tightened and seals are fitted correctly.

8. An even balance between lubricant volume and wire rope travel speed is
required to achieve an even lubricant film combined with optimum
penetration.

9. Once the optimum lubricant coverage is achieved, run the complete rope
at a consistent speed though the Viper Mid collar.

10. Note that the Viper Mid collar with flexible seals is not a pressure vessel
and is not designed to hold pressure. The grease pressure is generated
by both the pump and the action of the rope travelling through the
lubricant chambers in the seal. The Viper grease pump should not be
operated with the wire rope stationary.

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7.0 Lubricant Penetration

To inspect internal lubricant penetration a sharp spike or heavy-duty screwdriver
to open up the wire rope. Alternatively, two pipe wrenches secured one metre
apart, and rotated in opposite directions will allow visual inspection.

Lubricant penetration to the wire rope core is often difficult due to the followi ng :

• Wire rope design, particularly anti-spin and locked core wire ropes.

• Dirty or contaminated wire ropes.

(Use of a Viper Wire Cleaner is recommended)

• Ropes contaminated with solid used lubricant coating s .

(Use of a Viper Wire Cleaner is recommended)

During the wire rope operation, the rope movement onto the drum and over
sheaves is known to assist with the lubric a nt penetration.

If an NLGI#2 grade grease is used it may be necessary to pre-heat the lubricant
at ambient temperatures below 5 degrees C (41 F) to ensure adequate
penetration. Check with lubricant suppliers for method of pre-heating and
individual lubricant specifications. Be sure that the lubricant used will adequately
protect your wire rope from corrosion and wear.

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8.0 Equipment Specifications
Drum Pump

Maximum operating air pressure 120 psi
Pump ratio 45:1
Flow rate approximately 4,500 gram per min
Volume of compressed Air 250L/min at 7 bar

Guideline pressures are as follows:
Air Pressure for all Wire Rope Diameters 4 - 7 bar (60-105 psi)

Viper Collar

• Cast aluminium construction with enhanced mechanical properties and
excellent resistance to corrosion, heat treated to T6.

• Lugs tested to withstand 800kg of resistance.

• Coating: 3 coat treatment.

• Salt – Spray Resistance to ASTM B117-73 - 2,000 hours

• Humidity Resistance to ASTM D2247 - 1,000 hours

Seals

• Estimated average operational life – 10,000+ meters

• Shelf life 2-3 years (based on correct storage)

• Chemically resistant to commercially available mineral wire rope lubricants.

• The lubricator seals may be washed with a mild petroleum cleaner.

• Do not leave the seals to soak in cleaning fluid which may be detrimental to

their composition.

• It is important to store the seals away from UV light, the seals will be harmed
if left for extended periods in sunlight.

• Seals should be kept in a sealed plastic bag as supplied.

Scrapers

• 5083 Grade Aluminium Alloy High resistance to corrosion and ideal for marine
applications.

(Note: Lubrication Engineers reserves the right to change specifications as and when required.)

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9.0 Trouble Shooting

1. NO LUBRICANT ON WIRE ROPE AFTER START UP

a) Check lubricant container content.
b) Check lubricator pump air shut-off valve is open.
c) Check air pressure on gauge.
d) Check lubricant control valve is open (for High Speed Kits only).

2. INADEQUATE LUBRICANT COVERAGE

a) Utilize lubricant drum heater or change to lighter viscosity if ambient

temperature is 5ºC or below.

b) Increase air pressure and hence lubricant flow, until correct quantity

of lubrication is on wire rope.

c) Open lubricant flow control valve fully to increase lube flow.
d) Reduce wire rope speed to ensure complete coverage.

3. TOO MUCH LUBRICANT ON WIRE ROPE

a) Reduce volume of lubricant via the flow control valve (for High

Speed Kits only).

b) Increase wire rope speed through the lubricator collar.
c) Use a combination of both.
d) Investigate type of wire rope lubricant used.
e) Measure rope diameter and ensure correct seals in use.

4. LEAKING FROM COLLAR
a) Tighten collar clamping screws

b) Check correct Viper seal is being used for wire rope size.
c) Check air pressure, reduce if required.
d) Adjust Lubricant flow rate from control valve.
e) Check condition of seals for any damage.

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10.0 Safety Recommendations – Caution Level Rating

• Before installation of the wire rope lubricator onto the cable, ensure the
work area is clean and safe to work in with adequate space around the
cable attachment point, for attachment of the Viper Mid collar.

• Ensure buckles and straps, D shackles and attachment points used to
anchor the Viper Mid Lubr i c ator ar e rate d for a mini mu m WWL of 500 kg.

• Check hydraulic hose, couplings air lines and fittings for damage or wear,
before connecting to grease pump and Viper Mid lubricator collar. Carry out
visual inspection of the Viper Mid collar to ensure it has not been damaged
during transport or handling. Damage to the casing that prevents it from
sealing correctly will severely reduce the unit’s ability to force lubricant to
the ropes core and could be a potential safety hazard.

• Always ensure the return grease line feeds to a container of suitable size for
receiving the excess grease from the Viper Mid lubricator. Grease allowed
to flow from the return line without being captured may cause a serious slip
or environmental hazard.

• Note: Lubricants vary in their hazard and environmental ratings, please
ensure Material Safety Data Sheets for all lubricants used with the Viper are
kept in close proximity to the kit. Viper WRL Pty Ltd recommend a copy of
the lubricant in use MSDS is kept in the Aluminium carry case for reference
as required.

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11.0 Danger Rating

• Before attaching the Viper Mid MkII lubricator collar to the cable, you must
ensure the cable winch control has been locked out and tagged. Serious
injury or death may occur should the cable winching equipment be activated
while the Viper Mid MkII Lubricator is being fitted to the cable.

• When the Viper Mid MkII Lubricator has been assembled, attached to the
Cable and anchored in position, the lubrication system can be activated.
While in operation the grease pump can generate up to 5,500 PSI grease
pressure. Under no circumstances should the Viper Mid collar be opene d or
the grease hose disconnected while under pressure as this can cause
serious injury.

• While in operation the Viper Mid MkII Lubricator utilises both high pressure
air, up to 120 PSI max and high pressure grease up to 5,500 PSI. Always
wear appropriate PPE (Personal Protective Equipment) while carrying out
the cable lubrication operation.

• Suggested PPE includes, safety glasses, leather gloves, safety boots, long
sleeved shirts, high visibility vest, hard hat and hearing protection.

• Viper WRL Pty Ltd recommend to only use pumps, fittings, hoses and
accessories supplied or recommended by Viper WRL Pty Ltd. All of our
components have been tested to ensure they will work safely and effectively
for extended duty cycles. Using non-approved components may lead to
unexpected failure of the Viper Mid MkII Lubricator and / or its components
causing serious injury to maintenance personal.

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12.0 Viper Mid MKII Guarantee

The VIPER Mid MKII Wire Rope Lubricator Kits and all the components are
guaranteed for a period of 12 months from date of purchase against any fault of
manufacture or materi al failur e.

Fair wear and tear is expected of the unit and is not covered by warranty, tearing
of the seals due to broken wires or other obstructions are not covered by this
warranty.

Any parts to be claimed for warranty must be first returned to Viper WRL Pty Ltd
for inspection prior to warranty being granted.

NOTE: Commercially available wire rope lubricant NLGI 00-2.
(Approved Lubricants list available)

Viper WRL Pty Ltd
2 / 14 Stoddart Road, Prospect,
New South Wales, Australia, 2148

Web – www.ViperWRL.com
Email – [e-mail]

Ph: [phone]
Fax:[phone]