Graco G-JR Operation manual

3A8109A
EN
Instructions-Parts
G-JR Chemical
Injection Pump
Electric pump for injecting chemicals at well sites. For professional use only.
Not approved for use in explosive atmospheres or hazardous (classified) locations.
Not recommended for use with chemicals outside of the pH range of 4-9.
See page 2 for model information, including maximum
working pressure.
Important Safety Instructions
Read all warnings and instructions in this
manual and in the Harrier®EZ-JR
manual before using the equipment.
Save these instructions.

23A8109A
Contents
Related Manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Identification . . . . . . . . . . . . . . . . . . . . 5
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Flush Before Using Equipment . . . . . . . . . . . . . . 6
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 7
Choosing an Installation Location . . . . . . . . . . . . 8
Fluid Connections . . . . . . . . . . . . . . . . . . . . . . . . 8
Motor Electrical Connections . . . . . . . . . . . . . . . . 9
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Relief Procedure. . . . . . . . . . . . . . . . . 10
Flush the Equipment . . . . . . . . . . . . . . . . . . . . . 10
Prime the Pump . . . . . . . . . . . . . . . . . . . . . . . . . 11
Calibrate Chemical Dosage . . . . . . . . . . . . . . . . 11
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Remove G-JR Pump . . . . . . . . . . . . . . . . . . . . . 13
Replace Fluid Module . . . . . . . . . . . . . . . . . . . . 14
Replace Gear Assembly . . . . . . . . . . . . . . . . . . 15
Replace Motor . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Reinstall G-JR Pump . . . . . . . . . . . . . . . . . . . . . 15
Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
G-JR Chemical Injection Pump . . . . . . . . . . . . . 16
Kits and Accessories . . . . . . . . . . . . . . . . . . . . . 17
Technical Specifications . . . . . . . . . . . . . . . . . . . . 19
California Proposition 65. . . . . . . . . . . . . . . . . . . . 19
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 20
Related Manuals
Models
Manual No. Description
334993 Harrier EZ-JR Injection Pump Controller
Part No. Voltage Maximum Working Pressure
psi (MPa, bar)
25T650 12 VDC 2000 (13.7, 137)
25T651 120 VAC

Warnings
3A8109A 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When
these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific
hazard symbols and warnings not covered in this section may appear throughout the body of this manual where
applicable.
WARNING
FIRE AND EXPLOSION HAZARD
When flammable fluids are present in the work area be aware that flammable fumes can ignite or
explode. To help prevent fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources, such as cigarettes and portable electric lamps.
• Ground all equipment in the work area.
• Keep work area free of debris, including rags and spilled or open containers of solvent.
• Do not plug or unplug power cords or turn lights on or off when flammable fumes are present.
• Use only grounded hoses.
•Stopoperationimmediatelyifstaticsparkingoccurs oryoufeel ashock.Donotuseequipmentuntil
you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This
may look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical
treatment.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing andbefore cleaning, checking, or
servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings before each use. Replace worn or damaged parts immediately.
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause elec-
tric shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
or installing equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.

Warnings
43A8109A
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure and disconnect all power sources.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read Safety Data Sheet (SDS) to know the specific hazards of the fluids you are using.
• Store hazardous fluids in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury, including
eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes but is not
limited to:
• Protective eyewear, and hearing protection.
• Respirators,protectiveclothing, and gloves as recommended by the fluid and solvent manufacturers.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system com-
ponent. See Technical Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifica-
tions in all equipment manuals. Read fluid and solvent manufacturers’ warnings. For complete infor-
mation about your material, request Safety Data Sheet (SDS) from material supplier or retailer.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Checkequipmentregularly.Repair or replace wornor damagedpartsimmediatelywithgenuineman-
ufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations ormodifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
WARNING

Component Identification
3A8109A 5
Component Identification
Key:
Access the Harrier controller (3) and other components
inside the enclosure (1) by removing the lid (7) and
pump cover (4).
to
FIG. 1 G-JR Pump Components
1Enclosure
2 G-JR Pump Module
3 Harrier EZ-JR Controller
4 Pump Cover
6Base
7 Lid (included with Enclosure)
H Pump Inlet
J Pump Outlet
M Priming Port Plug
1
7
6
H
4
2
JM
FIG. 2 Access to Enclosure Components
6
4
7
3

Installation
63A8109A
Installation
Grounding
Pump: grounded through Motor Electrical Connec-
tions on page 9.
Fluid lines: use only electrically conductive lines.
Fluid supply container: follow local codes and regula-
tions.
Accessories
Install the following required accessories in the order
shown in Typical Installation, page 7, using adapters
as necessary. These required accessories must be sup-
plied and installed by the customer before use.
•Fluid Filter (Y-Strainer) (included in K): with a 60
mesh (250 micron) stainless steel element to filter
particles from the fluid before it reaches the pump.
•Fluid Shutoff Valves (L): shuts off fluid flow.
•Pressure Relief Valve (D): overpressure protec-
tion.
Flush Before Using Equipment
The equipment was tested with lightweight oil, which is
left in the fluid passages to protect parts. To avoid con-
taminating your fluid with oil, flush the equipment with a
compatible solvent before using the equipment. See
Flush the Equipment, page 10.
The equipment must be grounded to reduce the risk
of static sparking and electric shock. Electric or static
sparking can cause fumes to ignite or explode.
Improper grounding can cause electric shock.
Grounding provides an escape wire for the electric
current.

Installation
3A8109A 7
Typical Installation
FIG. 3 is an example of an installation with a G-JR
chemical injection pump. Your installation may differ
from what is shown here. The G-JR pump (A) is the only
component in FIG. 3 supplied by Graco. All other com-
ponents are supplied by customer.
Key:
A G-JR pump
B Power Source
CTank
D Pressure Relief Valve (Required)
E Inlet Line
F Outlet Line
G Pressure Relief Line
H Pump Inlet
J Pump Outlet, 1/4 in. npt
K Manifold Assembly (includes y-strainer)
L Fluid Shutoff Valve (outlet) (Required)
M Priming Port Plug
FIG. 3 Typical Installation
A
B
F
E
G
C
D
H
J
L
K
M

Installation
83A8109A
Choosing an Installation
Location
1. Select a location that will adequately support the
weight of the pump, as well as all plumbing and
electrical connections.
2. Always mount the pump upright.
3. Mount the pump above the top rim of the contain-
ment tank, if used, to prevent submersion.
4. If you have a mounting configuration that requires
installation in a manner different than depicted in
FIG. 3, please contact your Graco distributor.
Fluid Connections
1. Remove and discard the caps on the Pump Inlet (H)
and Outlet (J). See FIG. 1 on page 5.
2. Connect a 1/4 npt(f) fluid line from the fluid source to
the Pump Inlet (H).
3. Install a Pressure Relief Valve (D) on the outlet side
of the pump. See FIG. 3 on page 7.
NOTE: A Pressure Relief Valve (D) is available from
Graco (see Kits and Accessories on page 18) and can
be connected back to the tank ordirectly to the inlet side
of the pump.
4. Set the Pressure Relief Valve (D) at or below the
maximum working pressure of the pump.
5. Connect a 1/4 npt(f) Outlet Line (F) from the Pump
Outlet (J) to the injection point.
To reduce the risk of skin injection and damage to the
pump in the event of an outlet line blockage, ensure the
pressure relief valve (D) is set at or below the maxi-
mum working pressure of the pump.

Installation
3A8109A 9
Motor Electrical Connections
NOTE: Over-current protection is provided, for both AC
and DC models, within the enclosure (1).
The AC and DC models both havepre-wired controllers.
The power sources and connections differ as follows:
•For AC models (25T651), simply plug the power
cord (18) into a standard 115 VAC receptacle. See
FIG. 4.
•For DC models (25T650), connect red wire on the
controller (15) to the red wire on the power supply
(13), and the black wire on the pump (2) to the black
wire of the power supply (13).
To reduce the risk of electrical shock;
• All electrical wiring must be done by a qualified
electrician and complywith all local codes andreg-
ulations.
• Installthepump with a dedicated meansto discon-
nect the main power to the pump.
NOTICE
To avoid potential damage to equipment, verify that all
system valves are open before connecting power to
the pumps.
FIG. 4 AC Power Source
18

Operation
10 3A8109A
Operation
Pressure Relief Procedure
Follow the Pressure Relief Procedure whenever
you see this symbol.
NOTE: Always discharge fluid into an approved con-
tainer or location.
1. Disconnect electrical power to the pump.
2. Shut off the inlet and outlet lines using the Fluid
Shutoff Valves (L). See FIG. 3 on page 7.
3. Slowly loosen the pump outlet (J) fitting to relieve
downstream fluid pressure. See FIG. 1 on page 5.
4. Disconnect and cap the Inlet (E) and Outlet (F)
Lines.
Flush the Equipment
• Check fittings for leaks and tighten as necessary.
• Flush with a fluid that is compatible with the fluid
being dispensed and the equipment’s wetted parts.
1. Perform the Pressure Relief Procedure.
2. Connect the Pump Inlet (H) to the flushing fluid sup-
ply source. See FIG. 1 on page 5.
3. Connect the Pump Outlet (J) to a waste reservoir.
4. Run the pump until the dispensed fluid is predomi-
nately flushing fluid.
5. Perform the Pressure Relief Procedure.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection and splashing
fluid, follow the Pressure Relief Procedure when
you stop dispensing and before cleaning, checking, or
servicing the equipment.
To avoid fire andexplosion, always ground equipment
and waste container. To avoid static sparking and
injury from splashing, always flush at the lowest pos-
sible pressure.