wire rope lubricant applicator made in china

Proper lubrication of wire rope will extend operational life and increase safety. Done correctly, it lubricates exterior surfaces as well as the inside wires and core. Proper lubrication will help reduce friction as the individual wires move over each other, and provide corrosion protection.However, lubricating wire ropes can be difficult. Manual lubrication via drip, brush, spatula or rubber glove method is a messy, time-consuming maintenance task and can be hazardous to the environment.

The Viper Wire Rope Lubricator is a much better solution. The Viper Mid MK II provides fast, effective one-pass lubrication of wire ropes from 5/16 in (8 mm) to 2 5/8 in (67 mm) in diameter, at speeds up to 6,670 ft (2,033 m) per hour. It eliminates the slow, labor-intensive task of manual lubrication, at the same time achieving more thorough results by forcing LE’s robust wire rope lubricant under high pressure (up to 5,500 psi) right to the core of the wire rope.

The Viper Wire Rope Lubricator can be used in any application where wire rope can be drawn through the collar of the lubricator, including the following typical applications:

The Viper Wire Rope Lubricator consists of a lubricator collar assembly that houses polyurethane seals suited to a specific wire rope size. The assembly is clamped around the rope and anchored to a fixed point. The rope is then pulled through the collar. The steel scraper plates pre-clean the rope by scraping dirt, debris and old lubricant from the rope and protect the seals from loose strands, flattening them out before new lubricant is applied.

As the lubricant is applied with the high-pressure, high-flow grease pump, it forces the lubricant between the strands to the wire rope core. The result is a fully lubricated wire rope with a smooth minimal film of lubricant on the outer strands.

The collar is the heart of the Viper MK II. Constructed from high-grade cast aluminum with a robust protective coating, the collar is completed with stainless steel hardware to provide maximum corrosion protection. The MK II collar has built-in handles, making it easy to carry in one hand. One person can easily attach the Viper to the rope.

LE carries the complete standard kit and all necessary components for operation. Configuring the kit is simple. The selection of the seals and scraper plates is based on wire rope size. If you have more than one wire rope size, additional scrapers and seals can be purchased.

We also carry some of the best wire rope lubricants found in the market to provide you with an entire solution. We recommend that you use Wirelife® Almasol® Coating Grease (452-453) with the Viper Wire Rope Lubricator

Wirelife Almasol Grease is available in NLGI 00 (452-PL, 452-QD, 452-DR) and NGLI 0 (453-PL, 453-QD, 453-DR) grades, both of which are extremely tacky and water resistant and have exceptional penetrating ability. They provide EP protection and exceptional corrosion protection, even in underwater applications

In addition to wire rope lubrication, LE is happy to offer lubricant and reliability recommendations for a variety of industries and applications, and to provide product-specific data on all of our items to help you make the right decision.

To learn more about the Viper Wire Rope Lubricator or about LE’s enhanced lubricants, lubricant training, oil analysis, filtration, lube rooms, breathers, sight glasses or other lubricantreliability solutions, please contact us today.

We will carry out lubrication on our 103 mm wire in the coming days. This will be the third time this has been conducted, and I am extremely satisfied with the results. No wastage due to drop off during application and very good penetration.

Bridon Ropes has used Masto machines in its factories for over 10 years, in cases where a special lubricant coating is required on particular wire ropes. Over the years the machines have given dependable service over a wide range of rope sizes and constructions, and have given satisfactory seal lives.

After having used the Masto unit for approximately 2 ½ years, we are more than satisfied with the unit. It is a clean and efficient way of greasing wires. Before we got the unit, greasing wires was a hard task, but now the unit is doing the work for us and the wires are greased properly and evenly.

The undersigned surveyor to Det norske Veritas was present when the “MASTO” wire lubricator was demonstrated on two wire dimentions. After being greased, the wires were split apart, and we can confirm that the grease had penetrated through the whole cross-section of the wires.

We have tested different types of wire rope lubricators and can ensure you that we are very satisfied with your product. We would definitely go for Masto lubricators should the need for such a product arise again.

I can confirm that the ‘Maesto’ wire rope lubricator has been in use on the vessels under my control for several years, during which time it has proved to be a highly effective tool to assist particularly in maintaining the wire ropes of the deck cranes in good order, despite the most ardous operating conditions.

After having used the MASTO unit for approximately one year, we are very satisfied with the unit. It is a safe and clean way of greasing wires. It has proved to be a timesaving tool, compared to brush, cloth etc.

Today we have used the Lubricator for the first time. One word: Amazing! 2 hours instead of two days, no backache, 60 Kg grease instead of 250 Kg, clean dungarees, no mess everywhere around. It’s a great advisable product. I will recommend the wire lubricator to my collegues.

Wire rope lubricant featuring advanced pseudoplastic rheology. BIOGEN WIRESHIELD demonstrates industry leading corrosion protection, protecting ropes from their primary failure mode. BIOGEN WIRESHIELD is a dark grey gel, however, it is designed to immediately transform into a fluid consistency under shear to aid penetration into the core of the rope. BIOGEN WIRESHIELD then returns back to a grease consistency. This transformation ensures that the lubricant resists dripping and fling.

BIOGEN WIRESHIELD is ideal for lubrication of all types of wire ropes. It is also ideal for equipment such as winches, hoists, drag lines, large chains, open gears,

KEMTREE LUBRICANT APPLICATOR is a simple mechanical device that significantly improves the carryover of Dry Drawing Lubricants on Steel and Stainless Steel wires.

A Lubricant Applicator is a spring-loaded device with 3 rollers. The rollers are made of high-quality alloy steel and carefully hardened for optimum performance.

The Applicator fits in all Standard Die Boxes of a Wire Drawing Machine. It is to be clamped on the wire without cutting it, thus avoiding the cumbersome process of threading the wire on the machine.

Our users can always expect excellent performance from any one of our Kirkpatrick wire rope lubrication systems. Their superb engineering provides unmatched strand lubrication and cleaning benefiting customers in any industry where wire rope maintenance is a priority. The Wire Rope Surface and groove pattern are scraped clean of penetration blocking debris and product buildup as the wire rope surface is uniformly coated with new lubricant. Every space within the wire rope open to receive the newly applied wire rope lubricant is filled.

Optimum penetration occurs as the wire rope being serviced passes through a controlled 100% pressurized immersion within the system’s internal seal lubrication chamber. This immersion displaces any entrapped surface moisture within the rope’s internal strands and replaces it with the newly applied coating product. You can trust Kirkpatrick systems’ functionality with high- and low-viscosity coatings. Higher viscosity coating products maximize fluid film support against strand rubbing that can shorten any working ropes life due to friction wear. In the event your application requires low viscosity coatings such as a mining friction hoist; our systems easily apply those products as well accommodating high wire rope travel speeds.

Wire rope or cable is used for a wide variety of purposes ranging from stationary service, such as guys or stays and suspension cables, to service involving drawing or hoisting heavy loads. In these various services, all degrees of exposure to environmental conditions are encountered. These range from clean, dry conditions in applications such as elevator cables in office buildings, to full exposure to the elements on outdoor equipment. This could include immersion in water that can be encountered on dredging equipment to exposure to corrosive environments, such as acid water,

found in many mining applications. These and other operating factors require that wire ropes be properly lubricated to provide long rope life and maximum protection against rope failure where the safety of people is involved.

A wire rope consists of several strands laid (helically bent, not twisted) around a core. The core can be a rope made of hemp or other fiber, or may be an independent wire rope or strand. Each strand consists of several wires laid around the core, which usually consists of one or more wires but may be a small fiber rope. The number of wires per strand typically ranges from 7 to 37 or more.

Each wire of a wire rope can be in contact with three or more wires over its entire length. Each contact is theoretically along a line, but this line actually widens to a narrow band because of a deformation under load. As load is applied, and as a rope bends or flexes over rollers, sheaves, or drums, stresses are set up that cause the strands and individual wires to move with respect to each other under high contact pressures. Unless lubricating films are maintained in the contact areas, considerable friction and wear result from these movements.

One of the principal causes of wire rope failures is metal fatigue. Bending and tension stresses, repeated many times, cause fatigue. Eventually, individual wires break and the rope is progressively weakened to the extent that it must be removed from service. If lubrication is inadequate, the stresses are increased by high frictional resistance to the movement of the wires over one another, fatigue failures occur more rapidly, and rope life is shortened.

Another principal cause of rope failure is corrosion. This covers both direct attack by corrosive materials, such as acid water that may be encountered in mines, to various forms of rusting. To protect against corrosion, lubricant films that resist displacement by water must be maintained on all wire surfaces.

Wear, deterioration, or drying out of the core result in reduction of the core diameter and loss of support for the strands. The strands then tend to overlap, and severe cutting or nicking of the wires may occur. The lubricant applied in service must be of a type that will penetrate through the strands to the core to minimize friction and wear at the core surface, seal the core against water, and keep it soft and flexible.

During manufacture, wire rope cores are saturated with lubricant. A second lubricant, designed to provide a very tenacious film, is usually applied to the wires and strands to lubricate and protect the wires and to help keep (seal) the lubricant in the core as they are laid up. These lubricants protect the rope during shipment, storage, and installation.

Much of the core lubricant applied during manufacture is squeezed out when the strands are laid, and additional lubricant is lost from both the core and strands as soon as load is applied to a rope. As a result, in-service lubrication must be started almost immediately after a rope is placed in service.

Proper lubrication of wire ropes in service is not easy to accomplish. Some of the types of lubricants required for wire ropes may not be easy to apply, and often wire ropes are somewhat inaccessible. Various methods of applying lubricants are used, including brushing, spraying, pouring on a running section of the rope, drip or force feed applicators, and running the rope through a trough or bath of lubricant. Generally, the method of application is a function of the type of lubricant required to protect a rope under the conditions to which it is exposed.

These requirements necessitate some compromises. Wire rope lubricants may be formulated with asphaltic or petrolatum-based material and contain rust preventives and materials to promote metal wetting and penetration. Diluent products are used in some cases for ease of application. Grease products containing solid lubricants such as graphite or molybdenum disulfide are also used. The challenges with greases are the ability of the lubricant to penetrate to the inner core strands and its attraction for dust and dirt buildup. Wire ropes are often used in applications operating near or on an ocean, bay, river, lake, or other waterway, and as a result require environmentally acceptable wire rope lubricants to minimize their impact on the environment.

Please contact us for Your application needs and our technical support team will give You the best lubricating solution!Welcome to Lubrita.com International Lubrita Distributors network and World wide Oils & Lubricants online stores.

Smart businesses look to safely extend the life of their wire ropes with the right specialized lubricant. But even that approach can have unwanted and unfortunate consequences because the lubricants that historically excel at extending the life of wire ropes are not environmentally acceptable.

That was the complex problem presented to Klüber Lubrication by Redaelli Tecna, a global leader in the production of steel wire ropes with over 200 years of experience. They needed an EAL (Environmentally Acceptable Lubricants) solution with a high drop point and a reasonable price point.

Klüberbio AM 92-142 is an environmentally acceptable lubricant that combines excellent load-carrying capacity, good anti-wear protection and strong anticorrosive properties to extend the life of your wires. It also exhibits excellent adhesion to metal surfaces and good water resistance, reducing lubricant consumption and labor.

It was developed as an effective EAL lubricant option for steel wire ropes operating under harsh conditions. Especially those application seen in the marine and offshore industry where wire ropes contact sea water, are exposed to extreme cold or hot climate conditions and the extreme loads experienced during active heave compensation operations.

The partnership was so successful, Redaelli Tecna now recommends Klüberbio AM 92-142 for initial and relubrication of their own steel wire ropes. Klüber Lubrication NA LP is looking for partners within North America that use EAL wire rope lubricants in their marine operations but are not getting the desired results.

The Kirkpatrick Group, Inc., manufacturer of Kirkpatrick Wire Rope Lubrication Systems has kept very busy since their story last appeared on these pages back in 2003.

points out their number one goal remains unchanged, and that goal is to provide clients with innovation, safety, and support for the care and maintenance of their Wire Ropes

"What is unique about the testimonials we"ve have received over the years is that they’ve come to us unsolicited through third parties. Their evaluations and opinions concerning the performance of our product came directly from their successful use of it in their wire rope preventative maintenance programs."

The use of wire rope pressure applicators has now become a mainstay in most wire rope maintenance applications worldwide since Kirkpatrick first introduced them to the world market in 1982. Wire rope pressure lubrication has changed the manner in which industries maintain their wire ropes on a worldwide basis simply because their use has established that the working life of wire rope has been extended. In addition, labor savings have proven to be as much as 50 times greater as compared to the labor costs and time spent using manually applied methods.

Since 1982, Kirkpatrick has gained a broad knowledge of what it takes to optimally apply wire rope dressings to wire rope, no matter what method is used. This a direct result of his own infield and daily troubleshooting experience over the last 34 years.

The bottom line is that preventative maintenance should supplement the original layup material of the wire rope and if that lay-up material is viscous enough it is an impossibility to go through the core, according to Kirkpatrick. This is because there is already a preexisting protective coating barrier there. (Or should be) “This is not a negative but a good thing, he says.” The goal is to keep the original lay-up material intact for as long as possible.

“The fact is that the most important time a wire rope can receive a coating is during the manufacturing process when each individual strand can be coated before the wire rope is closed. I always push customers to use as viscous a coating as possible. This is especially true in the mining industry where Hoist Ropes can travel at hundreds of feet per minute generating friction wear between the strands at a level beyond other industry’s performance levels. A viscous product may be a little more expensive; however, the rewards of a longer wire rope life more than justifies it’s consideration for any wire rope preventative maintenance program.”

“Protection against friction wear and strand rubbing is guaranteed with heavier viscosity wire rope lubricants marrying well to the original layup material. Our systems will apply any viscosity product including oils as stated previously. Therefore, my opinion in support of heavier viscosity wire rope lubricants is not generated from the shortcomings of our wire rope lubrication system in being able to apply these heavier viscosity or wire rope lubricants. We can perform with them all if they can be pumped. The viscosity range our systems can accommodate extends to an NLGI Grade 3 or NLGI Grade 4 grease.”

“I have never been one that supports oils being used on working ropes where friction wear is of high concern and adequate fluid film protection between the strands is a must. Oils only apply a microscopic layer protection against strand rubbing. They can also serve to emulsify and wash out the original layup material. By analogy, would you use an oil on your car wheel bearings or grease them? If oils are used in a wire rope maintenance project; it is necessary to treat the rope more often because once the original lay-up material is gone; the oils must take its place. The fact is that at application most of the oil runs off or through the rope in the event the lay-up material is gone.”

Currently, most wire rope contractors are being required to pressure lube their customers’ wire ropes in offshore field applications or before delivery to the drill ships or rigs. There is also so much out there yet to be learned. The sales growth Kirkpatrick has experienced over the years is related to the fact that they have a database of more than 10,000 clients involved to some degree in wire rope preventative maintenance.

“I sit at my desk every day and find that I have to send troubleshooting emails around the world. I thoroughly enjoy the process. I am exposed to every industry where wire rope is used involving many different cultures. They all have their style of doing business. However, they all have one thing in common: They need our support and experience in helping them understand the process and then require our follow through to support them and then know our after sale support is what we claim it is. I say this with no arrogance intended: We do it better than anybody and the repeat business that we receive from our users absolutely supports this claim.”

During pressure lubrication, wire rope passes through a 100% pressurized and controlled immersion many times faster than manual applications. This, in turn, reduces labor costs, improves safety as well as increases the working life of the wire ropes being treated. The outer surface and groove pattern are wiped clean of water and contaminants which then allows optimal penetration of the wire rope coating used. There is less lubricant waste and optimal fluid film support between the strands that always reduces friction wear.

“I thoroughly understand the end user’s maintenance operations because I used to be in the crane business. We had 400 cranes in our rental fleet dispersed to major construction projects worldwide. Therefore, we know through experience fairly well what will support them in their own maintenance requirements.” We know what and how to quote them, what they require, whether for offshore cranes, mooring lines for tankers or whatever it may be.” Kirkpatrick likes to remind those he deals with of the facts regarding pressure lubrication and straighten out the numerous misconceptions that come to him from the misinformed. “There is this idea that the pressure inside the lubrication collar may go as high as 5,000 psi. We decided to test a competitor’s system who was making this claim on one inch (25mm) six strand with their lubricant. The internal pressure ended up being approximately ten psi. We then used our system with the competitor’s same coating product. Our internal pressure was 100 psi. In either case, it is a far cry from the 5,000 psi which came from their presentation. Why? This is because this kind of internal pressure is an impossibility to achieve at any level because of the simple fact that no wire rope pressure lubricator is a closed hydraulic system. That seems to be the perception and this is not being helped by our competition’s own misunderstanding of the process.”

“Lubricant moves through and around the wire rope in the stationary pre-travel mode and then as the wire rope travels through the seals, more pressure is released as the wire rope removes the lubricant feeding into the seals. In any event, the amount of internal pressure is dependent on the strand density and the configuration of the Wire Rope it has to penetrate.”

“For informational purposes: Generate 100 psi input at a 50:1 ratio pump and at the very down stroke of the pump piston pressures surge to 5,000 psi for a second. This has nothing to do with the internal pressure of the lubrication collar. What controls the lubrication collar’s internal pressure is the amount of wire rope lubricant contained within it’s internal seals at any given moment. The maximum internal pressure we have ever witnessed or seen was 800 psi using a grease and that involved a double armored cable.”

Ninety-nine percent of the time the wire rope lubricant is not going through the core, according to Kirkpatrick. If the pressure lubricator is constructed correctly, it will fill every open space in the wire rope that is available to receive the load. This is contrasted with the broadly used manual hand application method where only shallow surface coating is achieved using a rag. “The main thing that I would emphasize is that people need to understand how pressure lubrication works and what the strengths of the systems are to eliminate their misconceptions.

The company has a wide variety of agencies that have come to depend on their pressurized lubrication systems. Among these are the U.S. Coast Guard, the U.S. Navy, Army, Army Corps of Engineers, NATO, Canadian Coast Guard, Australian Navy and Canadian Navy along with some other military organizations globally. He says he understand that all of those listed are military. However, he wants the reader to know that to get approved by these government agencies takes extremely intense verification by some of the top engineers in the world. He has accepted their input with an open mind over the last 30 years and the extremely well-engineered system he provides, in many cases, is a direct result of their design input that came from their own requirements involving their sophisticated wire rope preventative maintenance programs. “The names on our civilian user list would absolutely impress any reader as well. He says.” However, that list is something he keeps close to the vest. I have provided enough information and training to our competitors over the years. Let them do their own homework.”

The Naval Air Systems Command Chief of Naval Operations Preproduction Evaluation Final Report concluded that the Kirkpatrick Model SU35B Wire Rope Lubricator evaluated during their evaluation, appeared to have significant potential for reducing material usage and waste disposal costs. Significant labor savings were found to be possible due to the reduced labor required to perform cable cleaning and lubricating events.

Of equal importance: The wire rope lubrication system is a safer alternative than the previous method used because it does not require personnel to place grease on their gloves and wipe the crane cable. The cost analysis showed a 10-year return on investment (ROI) of approximately $350,900.60 and a break-even point of .41 years according to the Navy"s report.

The Navy Public Works Department, San Diego found the Kirkpatrick Model SU35B Wire Rope Lubricator system to increase productivity and reduce costs. Their results were that the automated wire rope lubrication system extends the life span of wire rope, reducing the costs of removing and disposing of worn out wire rope and the purchase and installation of replacement rope.

G&H Towing, Galveston, Texas USA treating 2,200 Feet of 51 mm Tow Line using the Kirkpatrick Model JU120 System & Dynagard Blue™ Environmental Wire Rope Lubricant.

Operating costs are also reduced because cranes are less frequently taken out of service to be refitted with new Wire Rope. The automated system cleans and lubricates Wire Rope at a rate of 50 feet to 250 feet per minute as compared to the manual rate of approximately one foot per minute.

“Cleaning and lubricating wire ropes on cranes using the old manual method took approximately five eight-hour workdays per crane. Using the automated system, wire rope on a crane can now be cleaned and lubricated in one eight-hour day. This represents significant savings in labor costs. The automated wire rope lubricator has reduced PWC San Diego’s annual cost of cleaning cables from about $320,000.00 a year to approximately $34,000.00, a yearly cost savings of approximately $286,000.00.”

Navy maintenance practices require that crane cables be periodically cleaned and lubricated. The cables are constructed of multiple wire ropes that have been twisted together. Cleaning and lubricating provide corrosion resistance and extend the service life of the cable. Cable performance is improved by eliminating additional drag caused by the buildup.

The first step in any crane cable maintenance program involves cleaning the cable to remove any accumulation of dirt, marine growth, old grease, rust, and small particles of metal from between the wire rope strand that form the cable. After cleaning the cable, grease is reapplied to allow the crane cable to achieve its top operating speed and hauling ability. Metals that are scraped off during the cleaning process are disposed of as hazardous waste.

The Kirkpatrick Model SU35B was unique among other systems because of its implementation of groove cleaners. The groove cleaners, located at the wire rope inbound end of the Kirkpatrick lubricator collar, remove contaminants, surface greases, and build-up in the inner strands of the cable before lubrication. One pass of the SU35B over the cable accomplishes both the cleaning and lubricating steps.

The system was found to eliminate and the use of degreaser for cleaning cables, reduce the generation of waste, (degreaser, rags, grease) during cleaning and lubricating, and to provide a safer working environment while improving the efficiency of the entire wire rope maintenance process. This is coupled with the need to reduce the amount of hazardous material (grease) applied to the cables.

The site arranged for the WRL to be temporarily attached to a forklift to achieve an angle for the lubrication collar to operate properly. The ability of any given site to mount the lubrication collar in such a manner is dependent upon available equipment resources. It is also important to optimize the speed at which the cable is pulled through the lubrication collar and the pressure with which the grease is applied.

Bob Kirkpatrick feels that his firm has designed the most efficient wire rope lubrication system available today. “We understand what is required to provide those we serve with the right system for their specific application before purchase and then to maximize the customer’s use of that system once it is received.”

Do your wire ropes, cables and draglines become rusted, corroded or frayed? You can protect your wire rope and cable from high stress loading, shock loading, jerking and heavy loads with LE"s full line of penetrating and coating wire rope lubricants. Whether you want lubricant to penetrate to the core or to coat and seal, LE has a full range of protective lubricant solutions, including wire rope lubricant applicators to reduce labor costs and ensure safe, reliable operation.

New Extended Warranty: Documented use of LE452, LE453 Wirelife™ Almasol Wire Rope Lubricant or Earthwise™ EAL Wire Rope Lubricant will double the Viper warranty period to 24 months.

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LUBEGARD Wire Rope Lubricants are patented, aquatically non-toxic & biodegradable. They contain a unique blend of corrosion inhibitors, thickeners and wear reducers. Both are ideal for all types of wire ropes and chains in a variety of services and environments.