Pumptec 112PVC Series Service manual

Pumptec, Inc | 700 McKinley St. NW, Anoka, MN 55303 | 763-433-0303 | www.pumptec.com
Please read and save these instructions. Read carefully before attempting to assemble, install, operate, or maintain.
Protect yourself and others by observing all safety information. Failure to comply with instructions could result in
personal injury and/or property damage in which Pumptec, Inc. will not assume any liability! Retain instructions for
future reference.
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112PVC-SERIES PUMP
PERFORMANCE FEATURES
• Long Life
• Leak to Suction Seal Design
• High-Efficiency
• Serviceability
• Durability
• Application Flexibility
• Chemical Compatibility
• Compact Design
• Enhanced Priming

Pumptec Operating Instructions and Parts Manual Pump 112PVC-Series
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2
UNPACKING
Remove all packing materials. Carefully remove the plunger
pumps from the shipping carton. Inspect for any damage that
may have occurred during transit. Check for any loose, missing,
or damaged parts.
The contents include 1 Pumptec pump and motor assembly.
SPECIFICATIONS
Maximum specifications refer to individual performance levels.
Maximum performance ratings are maximums and may be
conditional on other factors. Consult Troubleshooting section
when operating near any performance maximum. Refer to
individual pump data sheets for complete specifications, parts
list and exploded view.
Model 112PVC-Series –Simple, Single Plunger Pump
MAX PRESSURE ...................................... 200 PSI
OPEN FLOW ........................................... 2.3 GPM
SEALS............................................................ T-SEAL
O-RINGS.................................................... VARIES
INLET PORT ....................................... 1/4” F NPT
DISCHARGE PORT
............................... 1/4" F NPT
MAX FLUID TEMP ................................TO 140˚F
RPM (MAX)....................................................2000
MATERIALS OF CONSTRUCTION
BODY.................................................................. PVC
PLUNGER ............................................... CERAMIC
VALVES.......................................................... C-276
FASTENERS............................. STAINLESS STEEL
GENERAL SAFETY INFORMATION
Please read this manual before installing or operating pump to
provide safe operation and prevent equipment problems.
Observe the following symbols and definitions.
NOTE: Indicates important instructions which are not related
to hazards.
IMPORTANT: Indicates factors concerned with assembly,
installation, operation, or maintenance which could result in
damage to the machine or equipment if ignored.
Warns about hazards that MAY cause
minor personal injury or property damage if ignored.
Warns about hazards that COULD cause
serious personal injury, death or major property damage if
ignored.
Warns about hazards that WILL cause
serious person injury, death or major property damage if
ignored.
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PLEASE READ, SAVE AND REFER TO SAFETY
INSTRUCTIONS BELOW:
Pumps build up heat and pressure during
operation. Allow time for pumps to cool before handling or
servicing. Only qualified personnel should install, operate,
and repair pump.
IMPORTANT: For pumping liquids other than water, contact
your supplier.
Do not pump hazardous materials
(flammable, caustic, etc.) unless the pump is specifically
designed and designated to handle them.
To reduce risk of electric shock, always
disconnect pump from power source before handling or
servicing.
Any wiring of pumps should be performed
by a qualified electrician.
These pumps are not intended to be
submersed.
Pumptec, Inc. is not responsible for losses, injury, or death
resulting from a failure to observe these safety precautions,
misuse or abuse of pumps or equipment.
INSTALLATION
MOUNTING
Pump motor set can be mounted in any position EXCEPT with
pump head higher than motor. To minimize amp draw, noise
and vibration, use appropriate flexible hose to inlet and
discharge ports.
LOCATION
If the pump is used in extremely dirty or
humid conditions, it is recommended pump be enclosed. Do
not store or operate in excessively high temperature areas or
without proper ventilation.
The pumping system can be mounted where it is visible, but it
must be protected from rain, dirt and chemical spray or
splashing. The pump must never be installed on a vertical
surface with the pump head higher than motor.
WARNING!
CAUTION!
CAUTION!
CAUTION!
CAUTION!
WARNING!
WARNING!

Pumptec Operating Instructions and Parts Manual Pump 112PVC-Series
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PRE-OPERATION
DISCHARGE CONDITIONS
Open all valves in system prior to operation to avoid excessive
load on motor and system from a pressure spike. Follow the
instructions for proper system design. Refer to supplier if
assistance is needed.
PRESSURE REGULATION
Verify pressure regulation devices are operating correctly.
NOZZLES
Nozzles create pressure in most systems, and they become
larger with use. Larger nozzles decrease system pressure.
Verify the quality of nozzles prior to operation.
MOTOR SHAFT ROTATION
Motor shaft rotation must always be
counterclockwise in order to assure proper function of pump
or warranty may be void.
PUMPED LIQUIDS
Some liquids may require a flush between operations or
before storing. For pumping liquids other than water, contact
your supplier.
OPERATION
GENERAL OPERATING INFORMATION
Pressure is often created by forcing a volume of fluid (flow)
through a specific size hole (nozzle). Additionally, pressure can
be created by pumping into a non-expanding chamber.
Pressure is measured and stated in PSI –pounds per square
inch.
Flow is created based upon the pump displacement and speed
(RPM) of the motor. Pump plunger size affects flow based
upon the same RPM. The faster the motor speed, the greater
the flow. Flow is measured and stated in GPM –gallons per
minute.
The pump, driven by a motor or engine, draws fluid through a
set of valves into the pumping chamber and the fluid is then
forced out of a set of valves to exit the pump. The back and
forth movement of the plunger in the sealed pumping
chamber creates the suction and discharge actions.
Once the fluid has exited the pump it must be controlled until
it exits the nozzle or reaches the place it needs to go. This
control is achieved via the use of system components such as
an unloader or regulating valve. The pumps are positive
displacement pumps providing a specific amount of fluid
constantly while operating. This volume of fluid must be
directed out thru a nozzle or back to a tank because it cannot
be stopped completely without creating excessively high
pressure and risk of damage to pump, components, property
and person. It is recommended a safety device such as a
regulating valve be installed directly on pump head as
protection in case of a failure of another component. Pressure
switches can be used to automate pump operation, but they
must have a pressure regulating device installed as a safety
device.
Fluid can enter a pump either from a filtered tank or
pressurized fluid line.
It is common to use a tank with pumps that are mounted
above the pump. Filtration is important to maintain proper
function of the pump and system. The extent of filtration may
be greater based upon some uses such as misting with ultra-
fine nozzles.
INLET CONDITION CHECKLIST
Inadequate inlet conditions can cause serious malfunctions in
the best designed pump. Surprisingly, the simplest of things
can cause the most severe problems or go unnoticed to the
unfamiliar or untrained eye. REVIEW THIS CHECKLIST BEFORE
OPERATION OF ANY SYSTEM. Remember, no two systems are
alike so there can be no ONE best way to setup a system. All
factors must be carefully considered.
INLET SUPPLY should exceed the maximum flow being
delivered by the pump to assure proper performance.
•Open inlet shut-off valve and turn on water supply to avoid
starving the pump.
• Avoid closed loop systems especially with high temperature,
ultra-high pressure or large flows. Conditions vary with
regulating/unloader valve.
• When using an inlet supply reservoir, size it to provide
adequate liquid to accommodate the maximum output of
the pump, generally a minimum of 6-10 times the GPM
(however, a combination of system factors can change this
requirement).
INLET LINE SIZE should be adequate to avoid starving the
pump
• Line size must be a minimum of one size larger than the
pump inlet fitting. Avoid tees, 90-degree elbows or valves in
the inlet line of the pump to reduce the risk of flow
restriction and cavitation.
• The line MUST be a FLEXIBLE hose, NOT a rigid pipe, and
reinforced on SUCTION systems to avoid collapsing.
• The simpler the inlet plumbing the less the potential for
problems. Keep the length to a minimum, the number of
elbows and joints to a minimum (ideally no elbows) and the
inlet accessories to a minimum.
• Use pipe sealant to assure airtight, positive sealing pipe
joints.
CAUTION!

Pumptec Operating Instructions and Parts Manual Pump 112PVC-Series
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INLET PRESSURE should fall within the specifications of the
pump.
• High RPM, high temperatures, low vapor pressures or high
viscosity may increase acceleration loss of liquids.
• Optimum pump performance is obtained with +20 PSI (1.4
BAR) inlet pressure. With adequate inlet plumbing, most
pumps will perform with flooded suction.
• After prolonged storage, pump should be purged of air to
facilitate priming. Disconnect the discharge port to allow
liquid to pass through pump and measure flow.
BYPASS TO INLET –care should be exercised when
deciding the method of bypass from control valves.
• It is recommended that the bypass be directed to a baffled
reservoir tank, with at least one baffle between the bypass
line and the inlet line to the pump.
• Although not recommended, bypass liquid may be returned
to the inlet line of the pump if the system is properly
designed to protect your pump.
• A low-pressure, flexible hose should be used from the
bypass connection to the inlet of the pump.
• Caution should be exercised to avoid under sizing the bypass
hose diameter and length.
• Check the pressure in the bypass line to avoid over-
pressurizing.
USING CHEMICALS
Chemicals can be mixed into the fluid and it is necessary to
understand whether these chemicals will damage the pump or
other system components. Another way to put chemicals into
the fluid is with a downstream injector.
An injector works as a result of the difference of pressure
between the inlet side of injector and discharge side. In most
cases, the pressure on the discharge side cannot exceed 1/2 of
the inlet pressure. For example, 1000 PSI into an injector
should allow up to 500-600 PSI spray pressure on discharge
side. There are dual-function nozzles that permit high
pressure, chemical free rinse and low pressure, chemical
spray. These are convenient for the operator and will not harm
a properly designed system.
The advantages of an injector are:
Fewer items touching chemical, the chemical injection rate can
be controlled, and applying chemical at lower pressure
increases chemical use efficiency.
HEATING FLUID
The pumps may sometimes be used with downstream heaters
and precautions need to be taken to protect the system and
persons from harm. Refer to the skilled staff at the equipment
manufacturer for guidance and proper system care. Please be
aware that heated water expands, and additional pressure
release safety devices may be required.
SYSTEM DESIGN
A pump is the heart of every system and proper selection is
critical to equipment function and durability. If a pumping set
with excess flow is chosen, then energy and fluid is wasted.
Equipment effectiveness can decrease if excess pressure
results, and so can pump life.
TYPICAL APPLICATIONS AND THEIR PERFORMANCE
CONSIDERATIONS
PRESSURE CLEANING The optimal combination of PSI and GPM
for cleaning is a ratio of 1 GPM for every 300-400 PSI. This
combination maintains sufficient droplet size for cleaning force
and distance. If the flow is increased without an increase in
pressure, the cleaning impact does not increase with the
increased use of fluid. If pressure increases, and flow does not,
then the water droplet size reduces and has less impact force,
requiring closer cleaning distances and increased risk of
surface damage
PEST SPRAYING
This application can have specific chemical usage requirements
and application pressure limits, so use the included
information as a guide only. Refer to label requirements for
each specific chemical. Line Loss When choosing a pump for
spraying, pressure loss in the hose must be considered. The
pressure is greatest at pump and decreases over the length of
the hose. Typically, these systems utilize very long hoses, 200-
300 ft. is common, and requires a certain minimum amount of
performance to move the flow through the lengths of hose.
For example, a 3 GPM system will require (lose) 50 PSI per 50
ft. of 3/8” ID hose. A pump with only 60-70 PSI may not
provide the desired performance at the end of the hose. See
reference charts to assist in system design.
MISTING
It is critical to size the pump correctly in a misting application.
If insufficient flow is chosen, then proper atomization and
droplet size will not result. If excessive flow is chosen, then
unnecessary wear and wasted energy will occur in this very
demanding application. Refer to the nozzle Performance Chart
for your chosen nozzles to determine the required total flow at
desired pressure. For example, if 1000 PSI is desired from 20
pieces of ‘08 misting nozzles, then a minimum flow rate of 0.4
GPM is required. Allowances need to be made for losses from
tubing lengths and fittings, too. It would be unwise in this
situation to choose a 0.75 or 1.0 GPM pumping system.
Another consideration for misting concerns the routing of the
bypass fluid. DO NOT return bypass fluid from regulating valve
directly back to inlet of pump. The returned fluid will contain
large amounts of air bubbles that will cause cavitation and
damage in the pump head. Also, the small amount of returned

Pumptec Operating Instructions and Parts Manual Pump 112PVC-Series
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fluid can heat up rapidly and lead to further cavitation and
component damage. It is recommended to route bypass back
to inlet of filter to allow air bubbles to dissolve and water to
cool prior to entering pump. The pumps are shipped
assembled to a custom-made motor based upon your
specifications. It is not necessary to order a motor separately.
Communicate your specification requirements and the
supplier will assist with pump options. Please use the following
charts as a guide to understand the basic system
requirements. NOTE : nozzle sizes in the performance chart
are additive. For example, 2 pieces of ’02 nozzle equals the
performance of 1 piece of ’04.nozzles create restriction
(pressure) in the system. If unsure of the nozzle size needed
for desired performance, refer to nozzle Performance Chart. If
you are sure of your nozzle size, but unsure of which pump set
to choose, then use the nozzle Performance Chart along with
the Horsepower Chart to determine your required pump
specification. An example of how to use these charts together:
when you have 2 pieces of an ’02 nozzle and you want 500 PSI,
the nozzle Chart will tell you that 2 pieces of an ’02 nozzle has
a flow equal to 1 piece of an ’04 nozzle. At 500 PSI, an ’04
nozzle has a flow of 1.4 GPM. The performance specification is
1.4 GPM at 500 PSI.
STORING
For extended storing, or between uses in cold climates, drain
all pumped liquids from pump and flush with antifreeze
solution to prevent freezing and damage to the pump. DO NOT
RUN PUMP WITH FROZEN LIQUID.
NOTE: Each system’s maintenance cycle will be unique. If
system performance decreases, check immediately. If no wear
at 500 hours, check again at 1000 hours and each 500 hours
until wear is observed. Valves typically require changing every
seal change. Duty cycle, temperature, quality of pumped liquid
and inlet feed conditions all affect the life of a pump’s wear
parts and service cycle.
NOTE: Remember to service the regulator/uploader at each
seal servicing and check all system accessories and
connections before resuming operation.

Pumptec Operating Instructions and Parts Manual Pump 112PVC-Series
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NOZZLE PERFORMANCE CHART
FLOW RATE VS. PRESSURE
GPM (gallons per minute) @ PSI (pounds per square inch)
PSI
SS TIP #
60
80
100
200
300
400
500
2
0.25
0.28
0.32
0.45
0.55
0.64
0.71
3
0.37
0.42
0.47
0.67
0.82
0.96
1.10
4
0.49
0.57
0.63
0.89
1.10
1.26
1.40
6
0.73
0.85
0.95
1.34
1.64
1.90
2.10
8
0.98
1.13
1.26
1.79
2.20
2.52
2.80
10
1.22
1.41
1.58
2.24
2.74
3.16
3.50
12
1.47
1.70
1.90
2.68
3.29
3.79
4.24
15
1.84
2.12
2.37
3.35
4.11
4.74
5.30
20
2.45
2.83
3.16
4.47
5.48
6.32
7.07
30
3.67
4.24
4.74
6.71
8.22
9.49
10.61
HORSEPOWER CHART
Flow in
GPM
Horsepower required @ PSI (pounds per square inch)
25
50
75
100
125
150
175
200
225
250
275
300
0.25
0.004
0.008
0.012
0.016
0.020
0.024
0.027
0.031
0.035
0.039
0.043
0.047
0.5
0.008
0.016
0.024
0.031
0.039
0.047
0.055
0.063
0.071
0.078
0.086
0.094
0.75
0.012
0.024
0.035
0.047
0.059
0.071
0.082
0.094
0.106
0.118
0.129
0.141
1
0.016
0.031
0.047
0.063
0.078
0.094
0.110
0.125
0.141
0.157
0.173
0.188
1.25
0.020
0.039
0.059
0.078
0.098
0.118
0.137
0.157
0.176
0.196
0.216
0.235
1.5
0.024
0.047
0.071
0.094
0.118
0.141
0.165
0.188
0.212
0.235
0.259
0.282
1.75
0.027
0.055
0.082
0.110
0.137
0.165
0.192
0.220
0.247
0.274
0.302
0.329
2
0.031
0.063
0.094
0.125
0.157
0.188
0.220
0.251
0.282
0.314
0.345
0.376
2.25
0.035
0.071
0.106
0.141
0.176
0.212
0.247
0.282
0.318
0.353
0.388
0.423
2.5
0.039
0.078
0.118
0.157
0.196
0.235
0.274
0.314
0.353
0.392
0.431
0.471
(*) Where pump efficiency is 93%

Pumptec Operating Instructions and Parts Manual Pump 112PVC-Series
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MAINTENANCE
DISASSEMBLY AND REASSEMBLY
1. Remove pump from motor by removing front bolts.
2. Remove back bolts, washers, and then separate the
heads from the manifold.
3. Separate heads from plunger.
4. Remove retainer plate, plunger guide, seal ring, and
O-ring from head. Discard used o-ring, seal ring, and
plunger guide.
5. Grease new O-rings and seal ring. Insert O-rings onto
steps, seal ring onto deeper o-ring, and install
cartridge into head.
6. Grease new o-ring and seal ring. Place o-ring into
cartiridge, sealing onto o-ring, and install plunger
guide into cartridge.
O-Ring
Retainer
Plate
Seal ring
O-Ring
Cartridge
O-Ring
Seal ring
Plunger guide

Pumptec Operating Instructions and Parts Manual Pump 112PVC-Series
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7. Push cartridge and plunger guide into head and slide
retainer plate fully into slot.
8. Repeat steps 4-7 for the other head.
9. Grease plunger in stripped areas.
10. Insert each end of the plunger into one of the heads.
Note the orientation of the plunger that faces away
from valves.
11. Note orientation of valves. Inlet on bottom and
outlet on top.
12. Place manifold on top of heads. Note the orientation
for the inlet and outlet.
In
Out

Pumptec Operating Instructions and Parts Manual Pump 112PVC-Series
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13. Thread bolts with washers through heads into
manifold.
14. Tighten front bolts with washers to secure pump to
motor.

Pumptec Operating Instructions and Parts Manual Pump 112PVC-Series
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PREVENTIVE MAINTENANCE CHECKLIST
Check
Daily
Weekly
50 Hrs.
1500 Hrs.
3000 Hrs.
Clean Filters
X
Water Leaks
X
Descale Pump
X
X
Cam & Bearing
X
Seal Change
X
X
Valve Change
X
X
TROUBLESHOOTING CHART
SYMPTOM
POSSIBLE CAUSE(S)
CORRECTIVE ACTION
No water flow
1. Tank is empty, or water is not turned on
1. Fill tank or turn on water supply
2. Filter clogged
2. Clean filter
3. Pump valves clogged or damaged
3. Examine valves and clean or replace
4. Pump has lost prime
4. Follow priming procedure
Low pressure
1. Worn nozzle
1. Replace nozzle with new one of same size
2. Leak in high pressure hose or connections
2. Check hose and connections
3. Filter clogged
3. Clean filter
4. Pump valves clogged or damaged
4. Examine valves and clean or replace
Pump pulsates when spraying
1. Filter clogged
1. Clean filter
2. Pump valves clogged or damaged
2. Examine valves and clean or replace
Motor does not operate
1. Blown fuse or circuit breaker
1. Replace circuit breaker or fuse. Check circuit for wire
damage or component damage
Leaks seen under pump
1. Worn pump seals
1. Replace with new plunger and seals
2. Abrasives in solution have damaged pump seals
2. Mix chemical thoroughly and improve filter
Regulator leaks fluid from cap
1. Pressure is set too low
1. Set pressure higher to keep internals from moving too
much
2. Replace seal
For Repair Parts, call 763-433-0303
Please provide following information:
-Model number
-Serial number (if any)
-Part description and number as shown in parts list

Pumptec Operating Instructions and Parts Manual Pump 112PVC-Series
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Repair Parts Illustration for X-Series Pump
EXPLODED VIEW IMAGE
REPAIR PARTS LIST FOR X-SERIES PUMP
DESCRIPION
PART NO.
CONTENTS
Seal Kit, Viton
10106
O-Rings, seal rings, plunger guides, installation hardware,
cartridges, and small grease packet
* Retainer plate not included.
Valve Kit, Viton
10107
O-Rings, check valves, and small grease packet
KIT-A *Retaining plate sold separately
KIT-B
KIT-B

Pumptec Operating Instructions and Parts Manual Pump 112PVC-Series
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LIMITED WARRANTY
PUMPTEC ONE-YEAR LIMITED WARRANTY. PUMPTEC PLUNGER PUMPS, MODELS COVERED IN THIS MANUAL, ARE WARRANTED BY
PUMPTEC, TO THE ORIGINAL USER AGAINST DEFECTS IN WORKMANSHIP OR MATERIALS UNDER NORMAL USE FOR ONE YEAR AFTER
DATE OF PURCHASE. ANY PART WHICH IS DETERMINED TO BE DEFECTIVE IN MATERIAL OR WORKMANSHIP AND RETURNED. AS
PUMPTEC DESIGNATES, SHIPPING COSTS PREPAID, WILL BE, AS THE EXCLUSIVE REMEDY, REPAIRED OR REPLACED AT PUMPTEC’S
OPTION. FOR LIMITED WARRANTY CLAIM PROCEDURES, SEE “PROMPT DISPOSITION” BELOW. THIS LIMITED WARRANTY GIVES
PURCHASERS SPECIFIC LEGAL RIGHTS WHICH VARY FROM JURISDICTION TO JURISDICTION.
LIMITATION OF LIABILITY. TO THE EXTENT ALLOWABLE UNDER APPLICABLE LAW, PUMPTEC’S LIABILITY FOR CONSEQUENTIAL AND
INCIDENTAL DAMAGES IS EXPRESSLY DISCLAIMED. PUMPTEC’S LIABILITY IN ALL EVENTS IS LIMITED TO AND SHALL NOT EXCEED THE
PURCHASE PRICE PAID.
WARRANTY DISCLAIMER. A DILIGENT EFFORT HAS BEEN MADE TO PROVIDE PRODUCT INFORMATION AND ILLUSTRATE THE
PRODUCTS IN THIS LITERATURE ACCURATELY; HOWEVER, SUCH INFORMATION AND ILLUSTRATIONS ARE FOR THE SOLE PURPOSE OF
IDENTIFICATION, AND DO NOT EXPRESS OR IMPLY A WARRANTY THAT THE PRODUCTS ARE MERCHANTABLE, OR FIT FOR A
PARTICULAR PURPOSE, OR THAT THE PRODUCTS WILL NECESSARILY CONFORM TO THE ILLUSTRATIONS OR DESCRIPTIONS. EXCEPT AS
PROVIDED BELOW, NO WARRANTY OR AFFIRMATION OF FACT, EXPRESSED OR IMPLIED, OTHER THAN AS STATED IN THE “LIMITED
WARRANTY” ABOVE IS MADE OR AUTHORIZED BY PUMPTEC.
Technical Advice and Recommendation Disclaimer. Notwithstanding any past practice or dealings or trade custom, sales shall not
include the furnishing of technical advice or assistance or system design. Pumptec assumes no obligations or liability on account of
any unauthorized recommendations, opinions or advice as to the choice, installation or use of products.
Product Suitability. Many jurisdictions have codes and regulations governing sales, construction, installation, and/or use of products
for certain purposes, which may vary from those in neighboring areas. While attempts are made to assure that Pumptec products
comply with such codes, Pumptec cannot guarantee compliance, and cannot be responsible for how the product is installed or used.
Before purchase and use of a product, review the product applications, and all applicable national and local codes and regulations,
and be sure that the product, installation, and use will comply with them.
Certain aspects of disclaimers are not applicable to consumer products; e.g., (a) some jurisdictions do not allow the exclusion or
limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you; (b) also, some
jurisdictions do not allow a limitation on how long an implied warranty lasts, consequently the above limitation may not apply to
you; and (c) by law, during the period of this limited Warranty, any implied warranties of implied merchantability or fitness for a
particular purpose applicable to consumer products purchased by consumers, may not be excluded or otherwise disclaimed.
Prompt Disposition. A good faith effort will be made for prompt correction or other adjustment with respect to any product which
proves to be defective within limited warranty. For any product believed to be defective within limited warranty, first write or call
Pumptec. Pumptec will give additional directions. If unable to resolve satisfactorily, write to Pumptec at address below, giving and
serial number, invoice number and date, and describing the nature of the defect. Title and risk of loss pass to buyer on delivery to
common carrier. If product was damaged in transit to you, file claim with carrier.
Manufactured by Pumptec, Inc. 700 McKinley St. NW, Anoka, Minnesota 55303 U.S.A. 763-433-0303