Viper Maxi MK 2 Supplement
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Phone: +61 2 9636 5655 2
Assembly & Operations
Manual
1. Introduction 3
2. Viper Maxi MK 2 Kit Components Inclusions 4
3. Viper Maxi MK 2 Components Assembled Kits & Components 5
3.1.1 Viper Maxi MK 2 Kit Complete 180kg 5
3.1.2 Viper Maxi MK 2 Complete Collar 6
3.1.3 Viper Maxi MK 2 Pump Kit 180kg 7
3.1.4 Viper Maxi MK 2 Complete Hose 180kg 8
3.2.1 Viper Maxi MK 2 High Flow Kit Complete 180kg 9
3.2.2 Viper Maxi MK 2 High Flow Complete Pump Kit 180kg 10
3.2.3 Viper Maxi MK 2 High Flow Complete Hose 180kg 11
4. Assembly Instructions Viper Maxi MK 2 12
5. Ratchet Strap Buckle Assemblies –Ref: AW107 15
6. Operating Instructions Viper Maxi MK 2 16
7. Lubrication Penetration 18
8. Equipment Specifications 19
9. Trouble Shooting 20
10. Safety Recommendations –Caution Level Rating 21
11. Safety Recommendations - Danger Rating 22
12.
Guarantee 23
Contents
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Assembly & Operations
Manual
1. Introduction
The Viper Maxi MK 2 Wire Rope Lubricator is an Australian designed and
manufactured lubricator for wire rope sizes from 50mm to 165mm. 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 Maxi
MK 2 WRL improves operator safety and reduces the environmental impact of wire
rope lubrication for any size operation.
Key Features of the Viper Maxi MK 2 WRL Include:
1. The Collar is constructed from high grade aluminium with a high visibility
corrosion resistant coating.
2. The Viper Collar constructed of lightweight material and incorporates cast carry
handles for easier handling.
3. Unique polyurethane Seal design provides largest pressure contact area to ensure
maximum lubrication penetration.
4. Durable and wear resistant polyurethane Seals last thousands of metres in
normal service.
5. Seal and scraper size range to cater for rope sizes 50mm to 165mm.
6. Viper Maxi MK 2 Standard Kit:
•45:1 grease pump delivers lubricant at up to 4,500 grams per minute and
pressure up to 5,000 psi.
Viper Maxi MK 2 High Flow Kit:
•High pressure high flow 50:1 grease pump delivers lubricant at up to 13,000
grams per minute and pressure up to 5,500 psi.
7. Global distribution network which provides local customer support.
Viper Maxi MK 2 Collar with Seals Inserted
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Assembly & Operations
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2. Viper Maxi MK 2 Kit Component Inclusions:
1. Viper lubricator Collar, cast aluminium with inbuilt handles, includes lubricant
delivery line quick connect coupling and excess lubricant fitting.
2. High pressure high flow customised Viper 50:1 grease pump to suit 180kg drum
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
Note: Refer to drawings
3. Ten (10) metre, high pressure ¾” hydraulic hose complete with female quick
connect couplings on each end.
4. One (1) metre clear hose for excess lubricant discharge.
5. Two (2) x 4 metre ratchet straps rated to 1200kg.
6. Four (4) x “Bow” shackles.
7. Viper Collar shoulder carry strap.
8. Heavy duty aluminium storage case with stainless steel fixtures.
9. Polyurethane Seals & Aluminium Scraper Plates (ordered separately)
a) Sized to suit specific size ropes 50mm to 165mm
b) Refer to Seal & Scraper Selection Guide
10. Viper Wire Cleaners (optional accessory)
a) Available to suit a variety of ropes –refer to Selection Guide when ordering
Note: Seals, Scrapers and Cleaners sold separately
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Assembly & Operations
Manual
1. Remove all components from Viper Aluminium
carry case, unpack from packing materials and lay
out on a clean flat surface. Check all items are
present as per your purchase order.
2. Remove grease pump noting the air inlet isolation
valve, air regulator and high-pressure needle
control valve are preassembled onto the pump.
•Connect site specific compressed 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 into
contact with the lubricant.
•Note the Viper 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 grease container.
7. Connect the high-pressure grease hose to the
grease pump outlet via the quick connect coupling.
4. Viper Maxi MK 2 Assembly Instructions
(refer assembly video on website)
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Assembly & Operations
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8. Remove the Viper Collar from the packaging materials
and loosen the two clamping bolts allowing the Collar
to open.
9. Fit the Scraper Plates to the Viper Collar using the
counter sunk screws and the Allen Key provided.
NOTE: Scraper Plates are sized to suite the wire
rope as per the Seal & Scraper Selection Guide.
10. Fit the Viper Seals into the Viper Maxi Collar. Make
certain that the grease inlet holes on the Seal and
Collar are aligned.
NOTE: Seals are sized to suite the wire rope as per
the Seal & Scraper Selection Guide.
11. Clamp the lubricator Collar fitted with Seals and
Scrapers around the wire rope to be lubricated,
tightening the two handles.
•Face the Collar so the lubrication inlet is closest
to the rope's entry point- refer to image A below.
DO NOT attach the Collar with the lubrication
inlet at the furthest point from the rope's entry
point –refer to image B below.
•Locate the Collar so the optimum length of wire
rope can be lubricated in a single pass, this is
typically close to the winch drum.
12. Attached the clear plastic drain hose to the Viper Maxi
Collar. This hose is to deliver excess lubricant back to
the collection container.
13. Connect the high-pressure lubricant delivery hose to
the Viper Collar using the quick connect coupler.
4. Viper Maxi MK 2 Assembly Instructions Cont.
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Assembly & Operations
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14. To secure the Viper 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 rope 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 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 the air shut-off valve is
off, preventing the air from reaching the pump
motor. Set the air pressure regulator to 5.5 bar (80
psi) and adjust up to 7 bar (105 psi) if required.
4. Viper Maxi MK 2 Assembly Instructions Cont.
Viper Maxi MK 2 Lubricator is now assembled and ready for use.
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Assembly & Operations
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5. 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 until 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 lease 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 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 Resistant 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 lashings 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 to
frequent visual inspection and regular examination by a competent person. Web lashings shall be
withdrawn from service if there is a 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 vehicles 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 RTA ‘Load Restraint Guide.’
Cam A
Slot A
Handle B
Webbing
Quick Release C
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Assembly & Operations
Manual
With the Viper Maxi Wire Rope Lubricator assembled and mounted correctly as
per Assembly 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
clockwise 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 the air regulator is set to 5.5
bar (80 psi) and adjust up to 7 bar (105 psi) if required.
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
lubricant flow control valve by turning clockwise.
4. THE VIPER IS NOW CHARGED & READY FOR OPERATION.
5. Start the wire rope moving through the Viper Maxi 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.
6. 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 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.
6. Operating Instructions Viper Maxi MK 2
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Assembly & Operations
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6. Operating Instructions Viper Maxi MK 2 Cont.
7. 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
lubricant coating occurs.
•Alternatively reduce the rope speed until an even lubricant coating occurs.
8. If lubricant leakage occurs around the Collar, check the Collar is correctly
tightened and Seals are fitted correctly.
9. An even balance between lubricant volume and wire rope travel speed is required
to achieve an even lubricant film combined with optimum penetration.
10. Once the optimum lubricant coverage is achieved, run the complete rope at a
consistent speed through the Viper Maxi Collar.
11. Note the Viper Maxi Collar with flexible Seals is not a pressure vessel and is not
designed to hold pressure. The grease pressure is generated by 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 ropes stationary.
Rope Lubricated with Viper VCG-0
Unlubricated Wire Rope
Rope Lubricated with Viper VCG-0
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Assembly & Operations
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7. Lubricant Penetration
To inspect internal lubricant penetration, use a sharp spike or heavy-duty
screwdriver to open 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 following:
•Wire rope design, particularly anti-spin and locked core wire ropes.
•Dirty or contaminated wire ropes. (Using a Viper Wire Rope Cleaner is
recommended).
•Ropes contaminated with solid used lubricant coatings. (Using a Viper
Wire Rope Cleaner is recommended).
During the wire rope operation, the rope movement onto the drum and over
sheaves is known to assist with the lubricant penetration.
If an NLGI#2 grade grease is used it may be necessary to pre-heat the lubricant at
ambient temperatures below 5°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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Assembly & Operations
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8. Equipment Specifications
Drum Pump
Standard Kit High Flow Kit
Maximum operating air pressure 8 bar/120 psi 8 bar/120 psi
Pump ratio 45:1 50:1
Flow rate approximately 4,500 grams per min 13,000 grams
per min
Volume of compressed air 250 L/min at 7 bar 1.9mt³/min at
8 bar
Guideline pressures are as follows:
Air pressure for all Wire Rope Diameters 5.5 –7 bar (80-105 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 operation life –10,000 + metres
•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 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 sealed plastic bag as supplied.
Scrapers
•5083 Grade Aluminium Alloy high resistance to corrosion and ideal for
marine applications.
NOTE: Lubrication Engineering reserves the right to change specifications as and when required.
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Assembly & Operations
Manual
9. 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.
2. INADEQUATE LUBRICATION COVERAGE
a) Utilise lubricant drum heater or change to lighter viscosity if ambient
temperature is 5°C or below.
b) Increase air pressure and hence lubricant flow, until correct quantity of
lubricant 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.
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 size 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 and reduce if required.
d) Adjust lubricant flow rate from control valve.
e) Check condition of Seals for any damage.
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