1. Introduction
This manual provides essential information for the safe and efficient operation, installation, and maintenance of the ISHAN YGL-G series electric grease pumps. These pumps are designed for use in industrial applications, particularly with punching machines, to ensure consistent lubrication. Please read this manual thoroughly before operating the equipment.
2. Safety Information
WARNING: Failure to follow these safety instructions could result in serious injury or equipment damage.
- Always disconnect power before performing any maintenance or installation.
- Ensure proper grounding to prevent electrical shock.
- Use only recommended lubricants.
- Do not operate the pump if it is damaged or malfunctioning.
- Keep hands and clothing clear of moving parts.
- Installation and maintenance should only be performed by qualified personnel.
3. Product Overview
The ISHAN YGL-G series electric grease pumps are progressive-type lubrication systems designed for reliable and automatic grease delivery. Key features include:
- Pressure relief valve for precise pressure setting.
- Plunger-type one-way function for consistent flow.
- New oil suppression block design to prevent rollover.
4. Specifications
The YGL-G series offers various models distinguished primarily by their grease reservoir capacity. All models share common operational characteristics.
4.1 General Specifications
| Characteristic | Value |
|---|---|
| Power | 25W |
| Pressure | 100 kgf/cm² (approx. 9.8 MPa) |
| Flow Rate | 16 cc/min |
| Voltage Options | 24V, 220V, 380V |
| Texture of Wood (Material) | Cast aluminum |
4.2 Model-Specific Capacities and Dimensions
| Model | Capacity | Overall Height (mm) | Reservoir Diameter (mm) | Overall Width (mm) |
|---|---|---|---|---|
| YGL-G080 | 800 cc | 301 | 108 | 190 |
| YGL-G120 | 1200 cc | 300 | 129 | 205 |
| YGL-G200 | 2000 cc | 301 | 158 | 219 |
4.3 Mounting Dimensions (Common to all models)
| Characteristic | Value |
|---|---|
| Mounting Hole Spacing (Horizontal) | 95 mm |
| Mounting Hole Spacing (Vertical) | 22 mm |
| Mounting Hole Type | 3-M8 |
| Base Height | 53 mm |
5. Installation and Setup
Proper installation is crucial for the optimal performance and longevity of your grease pump.
5.1 Mounting
- Select a stable and accessible location on the punching machine or lubrication system.
- Ensure the mounting surface is flat and capable of supporting the pump's weight.
- Align the pump with the pre-drilled mounting holes or mark new ones according to the dimensional diagrams (Figures 2 & 3).
- Secure the pump using M8 bolts through the three mounting points.
5.2 Electrical Connection
- Verify the pump's voltage (24V, 220V, or 380V) matches your power supply.
- Connect the power supply to the pump's electrical terminals, ensuring correct polarity for DC models and proper phase connection for AC models.
- Ensure all electrical connections are secure and insulated.
- Properly ground the pump to prevent electrical hazards.
5.3 Lubricant Connection
- Connect the grease inlet (IN) to your grease supply line.
- Connect the grease outlet (OUT) to your lubrication distribution system.
- Ensure all connections are tight to prevent leaks.
- Fill the reservoir with the appropriate grease. Refer to the label on the pump for grease type recommendations.
6. Operation
Once installed and filled, the pump is ready for operation.
- Turn on the power supply to the pump.
- The pump will begin to deliver grease according to its internal programming or external control signals.
- Monitor the grease level in the reservoir and refill as needed.
- Observe the pressure gauge (if installed) to ensure the system is operating within the specified pressure range (100 kgf/cm²).
7. Maintenance
Regular maintenance ensures the longevity and optimal performance of your grease pump.
- Grease Refill: Regularly check the grease level in the transparent reservoir and refill before it runs empty. Use only clean, compatible grease.
- Cleaning: Keep the exterior of the pump clean and free from excessive grease or debris.
- Inspection: Periodically inspect all connections (electrical and grease lines) for leaks, wear, or damage.
- Filter Check: If your system includes an inline filter, inspect and clean or replace it as per your system's maintenance schedule.
8. Troubleshooting
This section addresses common issues you might encounter with your grease pump.
8.1 Pump Not Operating
- Check Power: Ensure the pump is receiving the correct voltage and that all electrical connections are secure.
- Motor Overload: Check for any obstructions or excessive back pressure that might be overloading the motor.
- Internal Fault: If power is present and no external issues are found, the motor or internal components may require professional inspection.
8.2 Insufficient Grease Delivery
- Grease Level: Verify the reservoir has sufficient grease.
- Clogged Lines/Filter: Inspect lubrication lines and any filters for clogs.
- Air in System: Bleed any air from the system if necessary.
- Pressure Setting: Ensure the pressure relief valve is set correctly.
8.3 Grease Leaks
- Loose Connections: Tighten all grease line connections.
- Damaged Seals: Inspect seals and O-rings for wear or damage and replace if necessary.
9. User Tips
- Consistent Grease Type: Always use the same type and grade of grease to avoid compatibility issues and potential system blockages.
- Regular Visual Checks: Make it a habit to quickly check the grease level and for any visible leaks before starting operations each day.
- Clean Environment: Keep the area around the pump clean to prevent contaminants from entering the grease reservoir.
10. Warranty and Support
For warranty information, technical support, or service inquiries, please contact your authorized dealer or the manufacturer. Keep your purchase receipt and product model information handy when contacting support.
