WIRE ROPE LUBRICATOR. The Wire Rope Lubrication Solution FEATURES & BENEFITS: The System APPLICATIONS.

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1 WIRE ROPE LUBRICATOR The Wire Rope Lubrication Solution The manual lubrication of wire ropes via the drip, brush, spatula or rubber glove method has always been a difficult maintenance task. Typically messy asphaltic or blackjack type products are employed which have coating abilities but very little lubrication or penetration properties. The VIPER Wire Rope Lubricator provides fast and effective lubrication of wire ropes from 5/16 (8mm) to 2-5/8 (67mm) in diameter, at speeds up to 6,670ft (2,000mt) per hour. It eliminates the slow and labor-intensive task of manual lubrication, at the same time achieving more thorough results by forcing quality lubricant under high pressure right through to the core of the wire rope. The System The system consists of the Lubricator Collar assembly which houses the polyurethane seals to suit the specific size rope. The assembly is clamped around the rope and anchored to a fixed point. The rope is then pulled through the collar as the lubricant is applied with a high pressure grease pump, forcing lubricant between the strands to the center or the rope. The result is a fully lubricated wire rope with a smooth minimal film of lubricant on the outer strands. The benefits over conventional drip and brush or spray systems are substantial. The Viper Wire Rope Lubricator operates at a higher pressure than most other lubricator collars on the market, this combined with the robust construction guarantees fast, safe and effective wire rope lubrication. FEATURES & BENEFITS: * SINGLE PASS LUBRICATION * NO MORE MANUAL GREASING * STOPS CORROSION/ PROTECTS ROPES * PENETRATES TO THE WIRE ROPE CORE * LESS MESS AND WASTE * FAST AND EFFICIENT- AT SPEEDS UP TO 6,670FT (2,000MT) PER HOUR * HIGH PRESSURE OPERATES up To 6,000 PSI * LUBRICATES ROPES FRom 5/16 (8MM) To 2 5/8 (67MM) APPLICATIONS * WHARF CRANES * SHIP CRANES * ROV CABLES * MINE WINDERS * MOBILE CRANES * OIL AND GAS PLATFORMS * ANCHOR ROPES * DECK WINCHES * OVERHEAD CRANES * SHIP LOADERS

2 VIPER Wire Rope Lubricator Kit The Viper Wire Rope Lubricator is available in both Kit and component form. The Kit includes all the equipment you need to get started. Simply order the Kit and select the seals and scrapers appropriate to the wire you are lubricating. Kit Components Viper Heavy Duty Collar 2x2mt (7ft) hold down chains 50:1 Grease Pump (high volume) 4x D shackles Polyurethane Seals (1 pair) Aluminum Heavy Duty Storage Case Steel Scrapers (1 set) Viper Rope Cleaner (Optional) Air Regulator with gauge LE Wirelife Almasol Coating Grease (optional) On/Off air control valve 4mt (13ft) high pressure hose 1 mt (3.5ft) clear drain hose WIRE ROPE LUBRICATOR Viper Collar The Collar is the heart of the VIPER Wire Rope Lubricator system. With robust steel construction and corrosion protection coating, the collar has two anchor holes at each end to enable it to be secured plus easy to use locking toggles to lock the two halves of the collar in place. The Collar allows for lubrication of Wire Rope from 5/16 (8mm) to 2-5/8 (67mm). There is a high pressure male hydraulic coupler for lubricant supply plus a low pressure male barb fitting for attaching the product drain hose. Each end has fittings for two steel Scraper Plates. Nominate your size of Scraper Plates & Seals when ordering the Kit. Viper Grease Pump This high pressure 50:1 ratio air operated grease pump with the standard kit sized to suite a 5 gallon (20kg) grease pail. The Kit comes with a drum cover, carry handle, follower plate and 4m (13 ) of high pressure hydraulic hose with a female quick connect hydraulic coupler on the end. Seals The Wire rope Lubricator Seals are made from a polyurethane material which is extremely durable and wear resistant, while at the same time being flexible to achieve excellent sealing under pressure. The seals come in pairs to suit each individual rope size and are identical so can be reversed if one end becomes worn. They are easily removed and changed for different size ropes or cleaning and storage after use. There are numerous different size seals to accommodate all size wire ropes from 5/16 (8mm) to 2-5/8 (67mm). Scrapers Steel Scrapers are fixed to the end of the Wire Rope Lubricator Collar to pre-clean dirty wire ropes and also to protect the seal from broken strands by flattening loose wires. There are numerous different size scrapers to accommodate all size wire ropes. Consult our Seal and Scraper Selection Guide to determine the right size Scrapers for your wire rope. LE Wirelife Almasol Coating Grease Lubrication Engineers recommends the use of LE Wirelife Almasol Coating Grease with the Viper Lubricator. LE Almasol Coating Grease is available in NLGI#00 LE452 or NLGI#0 LE453 both of which have exceptional penetrating ability. It is tacky and water resistant and will penetrate wire ropes to the core providing EP lubrication and corrosion protection, even in undersea applications

3 Lubricant Usage Estimate Use the charts below to estimate the amount of lubricant required for various wire rope sizes. ROPE SIZE COATING lbs / foot ROPE SIZE COATING kg / meter 3/8" mm /32" mm /32" mm " mm Imperial 1-3/16" /8" /16" /32" Metric 30mm mm mm mm /32" mm /32" mm /8" mm /32" mm Be advised that wire rope lubricant usage is dependent on a number of factors including: Lubricant in use Lubricant relative viscosity Rope speed Pump pressure Ambient temperature Rope type Rope age (new or used) Previous lubrication phone:

4 SEALS & SCRAPER SELECTION GUIDE Seals are designed for interference fit depending on the size and type of wire rope. For standard 6 & 8 strand ropes a seal interference fit of up to 3mm is allowable. For compact, non rotating or wireline type ropes which do not have valleys a maximum 1 mm interference fit is recommended. As these types of ropes are almost a solid section design they do not allow for the same mount of seal deflection within the collar. Seal Part No. Wire Rope Sizes Seal Sizes VIP-VSEAL8 5/16 to 3/8 / 8mm to 10mm 5/16 / 8 mm VIP-VSEAL10 7/16 to 15/32 / 11mm to 12mm 3/8 / 10mm VIP-VSEAL13 1/2 to 9/16 / 13mm to 14mm 1/2 / 13mm VIP-VSEAL14 19/32 to 5/8 / 15mm to 16mm 9/16 / 14mm VIP-VSEAL16 21/32 to 11/16 / 17mm to 18mm 5/8 / 16mm VIP-VSEAL18 3/4 to 25/32 / 19mm to 20mm 11/16 / 18mm VIP-VSEAL20 13/16 to 7/8 / 21mm to 22mm 25/32 / 20mm VIP-VSEAL22 29/32 to 15/16 / 23mm to 24mm 7/8 / 22mm VIP-VSEAL24 1 to 1-1/32 / 25mm to 26mm 15/16 / 24mm VIP-VSEAL26 1 to 1-1/8 / 25mm to 28mm 1-1/32 / 26mm VIP-VSEAL28 1-5/32 to 1-3/16 / 29mm to 30mm 1-1/8 / 28mm VIP-VSEAL30 1-1/4 to 1-5/16 / 31mm to 33mm 1-3/16 / 30mm VIP-VSEAL /32 to 1-3/8 / 34 to 35mm 1-5/16 / 33mm VIP-VSEAL /32 to 1-1/2 / 36mm to 38mm 1-3/8 / 35mm VIP-VSEAL /32 to 1-19/32 / 39mm to 41mm 1-1/2 / 38mm VIP-VSEAL41 1-5/8 to 1-3/4 / 42mm to 44mm 1-19/32 / 41mm VIP-VSEAL /32 to 1-13/16 / 45mm to 46mm 1-3/4 / 44mm VIP-VSEAL /32 to 1-31/32 / 47 to 50mm 1-13/16 / 46mm VIP-VSEAL50 2 to 2-3/32 / 51mm to 53mm 1-31/32 / 50mm VIP-VSEAL53 2-1/8 to 2-5/32 / 54 to 55mm 2-3/32 / 53mm VIP-VSEAL55 2-3/16 to 2-9/32 / 56mm to 58mm 2-5/32 / 55mm VIP-VSEAL58 2-5/16 to 2-3/8 / 59mm to 60mm 2-9/32 / 58mm VIP-VSEAL /32 to 2-1/2 / 61mm to 63mm 2-3/8 / 60mm VIP-VSEAL63 2-1/2 to 2-9/16 / 64mm to 65mm 2-1/2 / 63mm VIP-VSEAL /32 to 2-5/8 / 66mm to 67mm 2-9/16 / 65mm

5 Wire Rope Size Wire Rope Size Wire Rope Size Wire Rope Size Scraper Part No. Imperial Metric Scraper Part No. Imperial Metric VIP-VSC8 5/16 8 VIP-VSC38 1-1/2 38 VIP-VSC9 11/32 9 VIP-VSC /32 39 VIP-VSC10 3/8 10 VIP-VSC40 1-9/16 40 VIP-VSC11 7/16 11 VIP-VSC /32 41 VIP-VSC12 15/32 12 VIP-VSC42 1-5/8 42 VIP-VSC13 1/2 13 VIP-VSC /16 43 VIP-VSC14 9/16 14 VIP-VSC44 1-3/4 44 VIP-VSC15 19/32 15 VIP-VSC /32 45 VIP-VSC16 5/8 16 VIP-VSC /16 46 VIP-VSC17 21/32 17 VIP-VSC /32 47 VIP-VSC18 11/16 18 VIP-VSC48 1-7/8 48 VIP-VSC19 3/4 19 VIP-VSC /16 49 VIP-VSC20 25/32 20 VIP-VSC /32 50 VIP-VSC21 13/16 21 VIP-VSC VIP-VSC22 7/8 22 VIP-VSC52 2-1/16 52 VIP-VSC23 29/32 23 VIP-VSC53 2-3/32 53 VIP-VSC24 15/16 24 VIP-VSC54 2-1/8 54 VIP-VSC VIP-VSC55 2-5/32 55 VIP-VSC26 1-1/32 26 VIP-VSC56 2-3/16 56 VIP-VSC27 1-1/16 27 VIP-VSC57 2-1/4 57 VIP-VSC28 1-1/8 28 VIP-VSC58 2-9/32 58 VIP-VSEC29 1-5/32 29 VIP-VSC59 2-5/16 59 VIP-VSC30 1-3/16 30 VIP-VSC60 2-3/8 60 VIP-VSC31 1-1/4 31 VIP-VSC /32 61 VIP-VSC32 1-9/32 32 VIP-VSC62 2-7/16 62 VIP-VSC33 1-5/16 33 VIP-VSC63 2-1/2 63 VIP-VSC /32 34 VIP-VSC /32 64 VIP-VSC35 1-3/8 35 VIP-VSC65 2-9/16 65 VIP-VSC /32 36 VIP-VSC /32 66 VIP-VSC37 1-7/16 37 VIP-VSC67 2-5/8 67 WIRE ROPE MEASUREMENT GUIDE LE recommends that wire ropes be physically measured prior to ordering seals and scrapers as ropes in service may vary in size. Scrapers are supplied slightly larger than the actual wire rope size to allow for rope flexing. Determine the size of your wire rope(s). The Viper Wire Rope Lubricator can lubricate ropes from 5/16 (8mm) through 2-5/8 (67mm). It is recommended that wire ropes be physically measured prior to ordering seals and scrapers as ropes in service can stretch and sizes may vary. The illustrations show how to measure a wire rope LIA

6 Viper Wire Rope Lubricator Assembly and Operation Manual Page 1 ******************************************************************************************** Distributed by: ********************************************************************************************

7 Index Introduction 3 The VIPER Wire Rope Lubricator components... 4 Assembly drawing of all lubricator pump components Fig. 1 5 A drawing of the lubricator collar assembly Fig Assembly instructions.. 7 Operating instructions Trouble shooting 11 Safety Instructions Caution & Danger Guarantee Page 2

8 Introduction The VIPER wire rope lubricator is a new Australian designed and built lubricator for rope sizes from 8mm (5/16 ) to 67mm (2-5/8 ). It provides fast and effective lubrication of wire ropes, eliminating the slow and arduous task of manual lubrication. Lubrication of wire ropes with the Viper provides superior protection by forcing lubricant into the core of the rope at pressures up to 6,000 psi. Page 3 Features of the VIPER include: 1. Robust, heavy duty steel collar with corrosion resistant coating cm long polyurethane seals provide maximum rope contact area. 3. Polyurethane seals are extremely durable and wear resistant. 4. Seal and scraper size range to cater for rope sizes 8mm to 67mm. 5. High pressure 50:1 grease pump delivers up to 6,000 psi, to suit 20kg pail. 6. Global distribution network. Providing safe and effective wire rope lubrication at a realistic cost.

9 The Viper Kit includes the following components: 1. Heavy Duty Lubricator collar 2. One pair Polyurethane seals (as required 8mm / 5/16 to 67mm / 2-5/8 ) Page 4 3. One set (4) scraper plates (as required 8mm / 5/16 to 67mm / 2-5/8 ) 4. High pressure 50:1 grease pump to suit 20kg drum (other sizes available) 5. Dry break high pressure hydraulic coupler 6. Air shut off ball valve 7. Air service unit with gauge 8. One meter of clear hose for excess lubricant return to drum 9. 4mt high pressure hydraulic hose 10. Metal storage case 11. Two x 2mt anchor chains 12. Four x D shackles 13. Viper Wire Cleaner (Optional) 14. LE WireLife Almasol Coating Wire Rope Lubricant 15.9kg (Optional) Refer to Figure 1 on page five for an illustration of the lubricator components and relationship to each other, and Figure 2 on page six for an illustration of the lubricator collar.

10 Figure 1 - Lubricator Components & Setup Page 5

11 Figure 2 - Lubrication Collar, Seals & Scraper Plates. Page 6

12 Assembly instructions 1. Remove grease pump components and assemble as per instructions provided, attach the on / off ball valve and air service unit to the pump inlet. Page 7 2. Connect the 4mt high-pressure hose with the dry-break hydraulic coupler to the lubricator pump. 3. Attach the clear plastic drain hose to the Viper collar. This hose is to feed excess lubricant back to the drum or other retaining vessel. 4. Insert the grease pump and follower plate into a drum of high quality wire rope lubricant of NLGI 000 to NLGI 2 consistency. Note the lighter the consistency the more penetration will occur with the Viper lubricator. (Lubrication Engineers strongly recommend the use of LE WireLife Almasol Coating Cable Lubricant NLGI 00 / 0) 5. Connect the air supply to the air shut off valve on the grease pump. Ensure that your air shut-off valve is off, preventing the air from reaching the pump motor. Set the air pressure regulator to the required reading depending on the wire rope size. (refer operating pressures page 8) 6. Clamp the lubricator collar around the wire rope to be lubricated, tightening the two toggles. Always try to position the lubricator as near as possible to the winch. Face the collar so that the hydraulic coupling is at the rope inlet end when the rope is being moved through the collar. 7. To secure the lubricator collar you can use steel securing cable, chain or heavy duty slings with two D shackles. Secure one end of the cable / chain to one of the lugs on the wire entry end of the lubricator collar. The other end should be fixed to a suitable fixing position to prevent the lubricator collar from travelling with the wire rope. Replicate this for the second lug on the lubricator collar. 8. Note the steel securing cable / chain is in high tension and strain during operation. Please ensure that all fittings and cables are tightly secured prior to operation. 9. The lubricator collar must be able to freely swing laterally during the operation to ensure even wire rope rewind onto the drum. 10. Connect the high-pressure hose using the dry-break hydraulic coupler to the Viper Collar.

13 Operating Instructions 1. Wire rope lubricant a) Ensure that you have sufficient quantities of high quality, tacky, waterproof lubricant to complete the job. As a general guideline, lubricant consumption will vary from 0.2 to 1 kilogram per 10 metres of wire rope lubricated. This is dependent upon rope diameter, speed of application, rope design, lubricant used and condition of the wire rope. Page 8 b) For best results, the recommended wire rope lubricant is LE WireLife Almasol Coating Cable Lubricant NLGI 00 / 0, manufactured by Lubrication Engineers Inc. Fort Worth, Texas USA For details of your local LE distributor please contact: sales@viperwrl.com c) If an NLGI 2 grade grease is used it may be necessary to pre-heat the lubricant at ambient temperatures below 0 degrees C (32 F) due to different viscosity and properties of that lubricant. 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. 2. Operating Pressures Maximum operating air pressure 120 psi Pump ratio 50:1 Flow rate approximately 1,500gram per minute (Self levelling 20C) Guideline pressures are as follows: Air Pressure Wire Rope Diameter 6 Bar (80 psi) up to 20mm (13/16 ) 7 Bar (100 psi) 22mm 50mm (13/16 to 1-15/16 ) 8 Bar (120 psi) 52mm 67mm (1-15/16 to 2-5/8 ) Set required air pressure on gauge with shut-off valve closed to prevent lubricator pump from operating until the correct air pressure is set.

14 3. Operating Conditions The air pressure setting should be adjusted accordingly 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, reduce the air pressure setting and /or increase the wire rope speed through the lubricator collar until the correct amount of lubricant appears on the wire rope. Page 9 High air pressure settings will provide more effective lubricant penetration into the wire rope, but could also cause lubricant leakage at the collar ends. If leakage occurs, check the collar is tightened and increase wire rope winch speed or decrease air pressure to pump accordingly. An even balance between air pressure setting, wire rope winch speed and lubricant consumption is required. Viper Lubrication of Wire Ropes a) Open the air pressure line and set the correct air pressure on the air pressure gauge by adjusting the air pressure-regulating valve. (guideline pressures for various wire rope diameters are indicated previously) b) Open the air shut-off valve to allow air to feed the air motor pump. c) Allow sufficient time for the wire rope lubricant to completely fill the highpressure hose and high-pressure chamber in the seal. Wait until excess lubricant begins to appear in the low-pressure exit hose from the lubricator collar. This may take 20 to 30 seconds. d) Engage the wire rope winch and commence lubrication at speeds of up to 1,000 metres per hour depending on the rope size and lubricant in use. e) Visually inspect the wire rope during and after lubrication to ensure adequate lubricant penetration and external coverage is occurring. DO NOT OVER LUBRICATE. f) To inspect internal lubricant penetration a sharp spike or heavy-duty screwdriver or two pipe wrenches secured one metre apart, and rotated in opposite directions will allow visual inspection. Complete lubricant penetration is difficult with certain design ropes, particularly anti-spin and locked core wire ropes. Wire rope movement will assist lubricant penetration during operation.

15 g) When the lubrication of the wire rope has been completed clean the collar, hoses and other accessories before storage. The lubricator seals may be washed with a mild petroleum substance such as kerosene. Do not leave the seals to soak in cleaning fluid which may be detrimental to their composition. Page 10 h) It is important to store the seals away from UV light, the seals will be harmed if left for extended periods in sunlight. Wire Rope Lubricant Usage Guidelines Rope Size mm Coating Volume kg/m, LE2002/ LE Note actual usage will vary according to rope size, speed of travel, ambient temperature, rope design and lubricant used.

16 Trouble Shooting 1. NO LUBRICANT ON WIRE ROPE AFTER START UP Page 11 a) Check lubricant container content. b) Check lubricator pump air shut-off valve is open. c) Check air pressure on gauge. d) Check lubricant flow. 2. LUBRICANT WILL NOT FLOW a) Switch on lubricant heater, if ambient temperature is 0ºC or below (local supply) b) Change to lighter viscosity lubricant below 0ºC ambient temperature. c) Pre-heat lubricant in lubricant drum. d) Increase air pressure and hence lubricant flow, until correct quantity of lubrication is on wire rope. e) Reduce wire rope speed to ensure complete coverage. 3. TOO MUCH LUBRICANT ON WIRE ROPE a) Reduce air pressure slowly until correct amount of lubricant is on wire rope. (this will reduce air motor speed). b) Increase wire rope speed through the lubricator collar. c) Use a combination of both. d) Investigate type of wire rope lubricant used.

17 Safety Recommendations Viper Assembly and Use Caution 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 Lubricator. Page 12 Ensure Cable / Chain, D shackles and attachment points used to anchor the Viper Lubricator are rated for a minimum WWL of 0.5 tonne. Check hydraulic hose, couplings air lines and fittings for damage or wear, before connecting to Grease Pump and Viper Lubricator Collar. Carry out visual inspection of the Viper body to ensure it has not been damaged during transport or handling, any damage to the casing that prevents it from sealing correctly will severely reduce the unit s ability to force lubricant to the ropes core. Always ensure the return grease line feeds to a container of suitable size for receiving the excess grease from the Viper Lubricator. Grease allowed to flow from the return line without being captured may cause a serious slip and 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. Lubrication Engineers recommend a copy of the Lubricant in use MSDS is kept in the Aluminium carry case for reference as required. Lubrication Engineers supply a copy of the Almasol Wirelife Coating Lubricant MSDS with any kits that include this product.

18 Safety Recommendations Viper Assembly and Use Danger Rating Page 13 Before attaching the Viper Lubricator 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 Lubricator is being fitted to the cable. When the Viper Lubricator has been assembled, attached to the Cable and anchored in position, the lubrication system can be activated. While in operation the internal grease pressure of the Viper can be up to 6,000 PSI. Under no circumstances should the Viper collar be opened while under pressure as this can cause serious injury. While in operation the Viper Lubricator utilises both high pressure air, up to 110 PSI and high pressure grease up to 6,000 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 had. Lubrication Engineers recommend to only use pumps, fittings, hoses and accessories supplied or recommended Lubrication Engineers. 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 Lubricator and / or its components causing serious injury to maintenance personal.

19 Guarantee The VIPER Wire Rope Lubricator Kit and all the components are guaranteed for a period of 12 months from purchase against any fault of manufacture or material failure. Page 14 Fair wear and tear is expected of the unit and is not covered by warranty, tearing of the seals due to broken wires etc are also not included in the warranty. Any parts to be claimed for warranty must be first returned to the Lubrication Engineers for inspection prior to warranty being granted. NOTE: Use of LE WireLife Almasol Coating Chain and Cable lubricant with the Viper will enable the user to DOUBLE their Viper warranty period to Two years

20 Safety Recommendations Viper Assembly and Use Caution 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 Lubricator. Ensure Cable / Chain, D shackles and attachment points used to anchor the Viper Lubricator are rated for a minimum WWL of 0.5 tonne. Check hydraulic hose, couplings air lines and fittings for damage or wear, before connecting to Grease Pump and Viper Lubricator Collar. Carry out visual inspection of the Viper body to ensure it has not been damaged during transport or handling, any damage to the casing that prevents it from sealing correctly will severely reduce the unit s ability to force lubricant to the ropes core. Always ensure the return grease line feeds to a container of suitable size for receiving the excess grease from the Viper Lubricator. Grease allowed to flow from the return line without being captured may cause a serious slip and 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. Lubrication Engineers recommend a copy of the Lubricant in use MSDS is kept in the Aluminium carry case for reference as required. Lubrication Engineers supply a copy of the Almasol Wirelife Coating Lubricant MSDS with any kits that include this product. Lubrication Engineers

21 Safety Recommendations Viper Assembly and Use Danger Rating Before attaching the Viper Lubricator 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 Lubricator is being fitted to the cable. When the Viper Lubricator has been assembled, attached to the Cable and anchored in position, the lubrication system can be activated. While in operation the internal grease pressure of the Viper can be up to 6,000 PSI. Under no circumstances should the Viper collar be opened while under pressure as this can cause serious injury. While in operation the Viper Lubricator utilises both high pressure air, up to 110 PSI and high pressure grease up to 6,000 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 had. Lubrication Engineers recommend to only use pumps, fittings, hoses and accessories supplied or recommended Lubrication Engineers. 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 Lubricator and / or its components causing serious injury to maintenance personal. Lubrication Engineers

22 1 Wire Rope Lubricator Frequently Asked Questions Does use of the VIPER Wire Rope Lubricator increase wire rope life comparative to traditional lubricating methods? valleys. The VIPER Wire Rope Lubricator will apply lubricant to the core of the wire rope sealing out moisture and protecting the strands against fretting, corrosion and fatigue failure. In marine applications such as ROV umbilical wires, ship deck winches, oil rig applications and wharf cranes the ropes typically corrode from the inside out. Also in many highly loaded applications such as large cranes and mine winders the ropes suffer fatigue failure due to the wire rope having friction from the strands rubbing against each other as the rope travels over sheaves and onto the drum. When using a Wire Rope Lubricant the rope is protected against corrosion and internal friction is reduced and therefore the Wire Rope life is improved. Major wire rope manufacturers such as Bridon suggest that lubrication with a pressure lubricator may increase wire rope life by up to 300% compared to unlubricated wire ropes. How time consuming is the VIPER Wire Rope Lubricator to use? In comparison to manual lubrication the VIPER wntime, once the VIPER Wire Rope Lubricator is set up and the wire rope speed versus pump speed is adjusted then the operation is virtually automatic. Lubrication can occur at speeds of up to 6,670 feet per hour (2,000 meters per hour). Why does the VIPER Wire Rope Lubricator come in a Kit form? The VIPER Wire Rope Lubricator Kit includes a complete suite of proven accessories that allows for rapid on-site deployment and enables the manufacturer to offer a standard 12 month warranty on all parts (excluding normal wear & tear). When the VIPER Wire Rope Lubricator is used in conjunction with Lubrication Engineers LE453 Wirelife coating lubricant the equipment warranty is doubled to 24 months. What is the weight of the VIPER Wire Rope Lubricator Collar? The VIPER Wire Rope Lubricator Collar weighs approximately 16kg / 35lbs with Scraper plates. The fact the unit is one piece with quick tighten toggles means it is more maneuverable and easier to set up than other two piece units. How do you select the correct Seal and Scraper size to suit a wire rope? Please refer to the document VIPER Wire Rope Lubricator Seal & Scraper Selection Guide. The seals and scrapers are installed into the collar to achieve the most effective sealing of lubricant between the collar and wire ropes. Seals are measured prior to ordering seals and scrapers as ropes in service can stretch and sizes may vary. How long will a set of Seals last when lubricating wire ropes? This depends on a number of factors including the condition of the wire ropes being lubricated and whether there are abrasive contaminants on the ropes prior to them entering the seal. However as an example a marine customer recently lubricated 7,000 metres / 4.3 miles of 1-3/8" (34mm) wire ropes while their ship was in dry dock. At the end of the lubrication session the customer feedback was that there was no leakage from the seal and that the seal had virtually no wear visible. It is estimated that in normal use VIPER Wire Rope Lubricator seals will last 40,000 50,000 feet (12,000 to 15,000 meters). How effective is the VIPER Wire Rope Lubricator with -Locked Core / Non Rotating / Armoured wire ropes? These types of wire ropes have extremely tightly wound strands with little space between the strands for wire rope lubricants to penetrate. While it cannot be guaranteed that the VIPER Wire Rope Lubricator will enable penetration of lubricant to traditional manual lubrication methods. It is even more important with these types of ropes to select an effective wire rope lubricant such as LE453 WireLife coating lubricant

23 Wire Rope Lubricator Frequently Asked Questions In what applications would you use the VIPER Wire Rope Lubricator? The VIPER Wire Rope Lubricator can be used in any application where wire ropes can be drawn through the collar, please refer to the applications listed below. Crane Wire Ropes Marine Applications Mining Applications Industrial Applications Static overhead cranes Ship deck winches Mine winder applications Overhead cranes Mobile cranes Tower cranes Ship cranes Wharf Cranes Ship Cranes Mooring lines Remote Operated Vehicles (ROV s) umbilical cables Stacker Reclaimer wires boom Bucket Wheel excavator boom wires Conveyor cable lubrication Wire manufacturers (coating while in production) Dredge cables Anchor cables Tug Boat winches Dam sluice gate lubrication Who are some of the customers that have successfully used the Wire Rope Lubricator? BHPB Iron Ore - Iron ore ship loaders OSG Ship Management Company Ship mooring lines BHPB Petroleum - Oil and Gas rigs at sea Woodside Petroleum - Oil and Gas rigs at sea Alcoa Aluminum - Ship loader Xstrata Coal Mine winder cable Mentrade OEM - Deck winch manufacturer Dof Subsea ROV umbilical wire lubrication Clough Engineering ROV umbilical wire lubrication Cervan Marine Ship loader MOL Tankships Ship Management Company Oil tanker SeaTrucks Marine pipe laying ship Acergy Marine Engineering Company VSL Cable manufacturers Pre-coating of cables to the core Mermaid Marine New vessel with submersible Marine Equipments Pte Ltd OEM Winch Supplier BHPB Olympic Dam Uranium Mine Mine Winder Waterway Constructions Bridge Building Crane Ropes LMS Ship Management Ship Cranes What technical support and backup is available for the VIPER Wire Rope Lubricator? Support for the VIPER Wire Rope Lubricator is available via , phone or fax. The VIPER Wire Rope Lubricator is a proven, high quality unit that features only the best standard of accessories to ensure long term reliable service. VIPER distributors worldwide are also available for onsite support and demonstration. How do I remove old built up lubricant and contaminants from Wire Ropes? We recommend the use of a Viper Rope Cleaner to remove contaminants from wire ropes prior to lubricating with the collar. It is matched in size and design to each individual wire rope and can strip away hard built up lubricant and other contaminants. The angular design effectively cleans out the valleys and outer strands to assist the Viper collar to lubricate and penetrate as required

24 White Paper LE WHITE PAPER Lubrication Basics for Wire Ropes Lubrication Basics for Wire Ropes Written by Jeffrey E. Turner Executive Vice President Lubrication Engineers, Inc Lubrication Engineers, Inc. The Lubrication Reliability Source

25 LE WHITE PAPER Lubrication Basics for Wire Ropes Wire rope forms an important part of many machines and structures. It is comprised of continuous wire strands wound around a central core. There are many kinds of wire rope designed for different applications. Most of them are steel wires made into strands wound with each other. The core can be made of steel, rope or even plastics. Wire ropes (cables) are identified by several parameters including size, grade of steel used, whether or not it is preformed, by its lay, the number of strands and the number of wires in each strand. Figure 1. Comparison of Typical Wire Rope Lays: A) Right Regular, B) Left Regular, C) Right Lang, D) Left Lang, E) Right Alternate A typical strand and wire designation is 6x19. This denotes a rope made up of six strands with 19 wires in each strand. Different strand sizes and arrangements allow for varying degrees of rope flexibility and resistance to crushing and abrasion. Small wires are better suited to being bent sharply over small sheaves (pulleys). Large outer wires are preferred when the cable will be rubbed or dragged through abrasives. There are three types of cores. An independent wire rope core (IWRC) is normally a 6x7 wire rope with a 1x7 wire strand core resulting in a 7x7 wire rope. IWRCs have a higher tensile and bending breaking strength than a fiber core rope and a high resistance to crushing and deformation. A wire strand core (WSC) rope has a single wire strand as its core instead of a multistrand wire rope core. WSC ropes are high strength and are used mostly as static or standing ropes Lubrication Engineers, Inc.

26 LE WHITE PAPER Lubrication Basics for Wire Ropes Wire ropes also have fiber cores. Fiber core ropes were traditionally made with sisal rope, but may also be made with plastic materials. The fiber core ropes have less strength than steel core ropes. Fiber core ropes are quite flexible and are used in many overhead crane applications. The lay of a wire rope is the direction that the wire strands and the strands in the cable twist. There are four common lays: right lay, left lay, regular lay and lang lay. In a right lay rope, the strands twist to the right as it winds away from the observer. A left lay rope twists to the left. A regular lay rope has the wires in the strands twisted in the opposite direction from the strands of the cable. In a lang lay rope, the twist of the strands and the wires in the strands are both twisted the same way. Lang lay ropes are said to have better fatigue resistance due to the flatter exposure of the wires. Wire ropes are made mostly from high carbon steel for strength, versatility, resilience and availability and for cost consideration. Wire ropes can be uncoated or galvanized. Several grades of steel are used and are described in Table 1. Table 1 Grade Tensile Strength (psi) Extra improved plow steel 245,000 to 340,000 Improved plow steel 220,000 to 300,000 Plow steel 195,000 to 258,000 Mild plow steel 168,000 to 225,000 Iron 100,000 Steel cable wire is stiff and springy. In nonpreformed rope construction, broken or cut wires will straighten and stick out of the rope as a burr, posing a safety hazard. A preformed cable is made of wires that are shaped so that they lie naturally in their position in the strand, preventing the wires from protruding and potentially causing injury. Preformed wire ropes also have better fatigue resistance than nonpreformed ropes and are ideal for working over small sheaves and around sharp angles. Wire Rope Lubrication Lubricating wire ropes is a difficult proposition, regardless of the construction and composition. Ropes with fiber cores are somewhat easier to lubricate than those made exclusively from steel materials. For this reason, it is important to consider carefully the issue of field relubrication when selecting rope for an application. Wire rope lubricants have two principal functions: 1. To reduce friction as the individual wires move over each other. 2. To provide corrosion protection and lubrication in the core and inside wires, and on the exterior surfaces Lubrication Engineers, Inc.

27 LE WHITE PAPER Lubrication Basics for Wire Ropes There are two types of wire rope lubricants, penetrating and coating. Penetrating lubricants contain a petroleum solvent that carries the lubricant into the core of the wire rope then evaporates, leaving behind a heavy lubricating film to protect and lubricate each strand (Figure 2). Coating lubricants penetrate slightly, sealing the outside of the cable from moisture and reducing wear and fretting corrosion from contact with external bodies. Figure 2. Foam Penetrating Type Wire Rope Both types of wire rope lubricants are used. However, because most wire ropes fail from the inside, it is important to make sure that the center core receives sufficient lubricant. A combination approach in which a penetrating lubricant is used to saturate the core, followed with a coating to seal and protect the outer surface, is recommended. Wire rope lubricants can be petrolatum, asphaltic, grease, petroleum oils or vegetable oil-based (Figure 3). Figure 3. Grease Lubed Wire Rope Petrolatum compounds, with the proper additives, provide excellent corrosion and water resistance. In addition, petrolatum compounds are translucent, allowing the technician to perform visible inspection. Petrolatum lubricants can drip off at higher temperatures but maintain their consistency well under cold temperature conditions. Asphaltic compounds generally dry to a very dark hardened surface, which makes inspection difficult. They adhere well for extended long-term storage but will crack and become brittle in cold climates. Asphaltics are the coating type. Various types of greases are used for wire rope lubrication. These coating types penetrate partially but usually do not saturate the rope core. Common grease thickeners include sodium, lithium, lithium complex and aluminum complex soaps. Greases used for this application generally have a soft semifluid consistency. They coat and achieve partial penetration if applied with pressure lubricators Lubrication Engineers, Inc.

28 LE WHITE PAPER Lubrication Basics for Wire Ropes Petroleum and vegetable oils penetrate best and are the easiest to apply because proper additive design of these penetrating types gives them excellent wear and corrosion resistance. The fluid property of oil type lubricants helps to wash the rope to remove abrasive external contaminants. Wire ropes are lubricated during the manufacturing process. If the rope has a fiber core center, the fiber will be lubricated with a mineral oil or petrolatum type lubricant. The core will absorb the lubricant and function as a reservoir for prolonged lubrication while in service. If the rope has a steel core, the lubricant (both oil and grease type) is pumped in a stream just ahead of the die that twists the wires into a strand. This allows complete coverage of all wires. After the cable is put into service, relubrication is required due to loss of the original lubricant from loading, bending and stretching of the cable. The fiber core cables dry out over time due to heat from evaporation, and often absorb moisture. Field relubrication is necessary to minimize corrosion, protect and preserve the rope core and wires, and thus extend the service life of the wire rope. If a cable is dirty or has accumulated layers of hardened lubricant or other contaminants, it must be cleaned with a wire brush and petroleum solvent, compressed air or steam cleaner before relubrication. The wire rope must then be dried and lubricated immediately to prevent rusting. Field lubricants can be applied by spray, brush, dip, drip or pressure boot. Lubricants are best applied at a drum or sheave where the rope strands have a tendency to separate slightly due to bending to facilitate maximum penetration to the core. If a pressure boot application is used, the lubricant is applied to the rope under slight tension in a straight condition. Excessive lubricant application should be avoided to prevent safety hazards. Key Lubricant Performance Measures Some key performance attributes to look for in a wire rope lubricant are wear resistance and corrosion prevention. Some useful performance benchmarks include high four-ball EP test values, such as a weld point (ASTM D2783) of above 350 kg and a load wear index of above 50. For corrosion protection, look for wire rope lubricants with salt spray (ASTM B117) resistance values above 60 hours and humidity cabinet (ASTM D1748) values of more than 60 days. Most manufacturers provide this type of data on product data sheets. Factors that Influence Wire Rope and Cable Performance Cable life cycle and performance are influenced by several factors, including type of operation, care and environment. Cables can be damaged by worn sheaves, improper winding and splicing practices, and improper storage. High stress loading, shock loading, jerking heavy loads or rapid acceleration or deceleration (speed of the cable stopping and starting) will accelerate the wear rate. Corrosion can cause shortened rope life due to metal loss, pitting and stress risers from pitting. If a machine is to be shut down for an extended period, the cables should be removed, cleaned, lubricated and properly stored. In service, corrosion and oxidation are caused by fumes, acids, salt brines, sulfur, gases, salt air, humidity and are accelerated by elevated temperatures. Proper and adequate lubricant application in the field can reduce corrosive attack of the cable Lubrication Engineers, Inc.

29 LE WHITE PAPER Lubrication Basics for Wire Ropes Abrasive wear occurs on the inside and outside of wire ropes. Individual strands inside the rope move and rub against one another during normal operation, creating internal two-body abrasive wear. The outside of the cable accumulates dirt and contaminants from sheaves and drums. This causes three-body abrasive wear, which erodes the outer wires and strands. Abrasive wear usually reduces rope diameter and can result in core failure and internal wire breakage. Penetrating wire rope lubricants reduce abrasive wear inside the rope and wash off the external surfaces to remove contaminants and dirt. Typical Rope Applications Many types of machines and structures use wire ropes, including draglines, cranes, elevators, shovels, drilling rigs, suspension bridges and cable-stayed towers. Each application has specific needs for the type and size of wire rope required. All wire ropes, regardless of the application, will perform at a higher level, last longer and provide greater user benefits when properly maintained. Through years of field experience, Lubrication Engineers has found that longer wire rope life can be obtained by using penetrating lubricants, either alone or when used in conjunction with a coating lubricant. Practical experience at a South African mine suggests that life cycles may be doubled with this approach. At one mine site, the replacement rate for four 44-mm ropes was extended from an average 18.5 months to 43 months. At another mine, life cycles of four 43-mm x 2073 meter ropes were extended from an average 8 months to 12 months. In another study involving 5-ton and 10-ton overhead cranes in the United States that used 3/8-inch and 5/8-inch diameter ropes, the average life of the ropes was doubled. The author attributes this increased performance to the ability of the penetrating lubricant to displace water and contaminants while replacing them with oil, which reduces the wear and corrosion occurring throughout the rope. A good spray with penetrating wire rope lubricant effectively acts as an oil change for wire ropes. In these examples, the savings in wire rope replacement costs (downtime, labor and capital costs) were substantial and dwarfed the cost of the lubricants. Companies who have realized the importance of proper wire rope lubrication have gained a huge advantage over those who purchase the lowest priced lubricant, or no lubricant at all, while replacing ropes on a much more frequent basis. About Lubrication Engineers A leader in lubricants since 1951, Lubrication Engineers, Inc., manufactures and markets premium lubricants formulated from highly refined base oils. Enhanced with proprietary additives, LE oils and greases provide unmatched performance in nearly any application operating in normal-to-severe conditions. All Lubrication Engineers lubricants are manufactured in an ISO 9001:2000 certified quality system at LE s state-of-the-art plant in Wichita, Kan., and are available worldwide. With its comprehensive offering of lubricants and related reliability products, LE provides its customers with increased profitability through longer equipment life, extended service intervals, reduction in energy use, fewer repairs and less need for inventory. References 1. American Iron and Steel Institute. (1985). Wire Rope Users Manual, Second Edition. p. 5-17, (1983). CRC Handbook of Lubrication, Volume 1. p Brewer, A. (1974). Effective Lubrication. p Lubrication Engineers, Inc.