Pumptec 112X Series User 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.
Refer to the following video to assist in pump reconstruction:
112X Pump Rebuild Tutorial
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112X-SERIES PUMP
PERFORMANCE FEATURES
• Long Life
• High-Efficiency
• Serviceability
• Durability
• Application Flexibility
• Chemical Compatibility
• Compact Design
• Enhanced Priming

Pumptec Operating Instructions and Parts Manual Pump 112X-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.
SPECIFICATIONS
Maximum specifications refer to individual performance levels
and may be conditional on other factors. Consult the
Troubleshooting section when operating near any performance
maximum. Refer to individual pump data sheets for complete
specifications, parts list, and exploded view.
Model 112X
MAX PRESSURE ...................................... 100 PSI
OPEN FLOW ........................................... 2.5 GPM
SEALS............................................................ T-SEAL
O-RINGS.......................................................... FKM
INLET PORT ....................................... 1/4” F NPT
DISCHARGE PORT
............................... 1/4" F NPT
MAX FLUID TEMP ................................TO 140˚F
MATERIALS OF CONSTRUCTION
BODY..........................................................................
HARDCOAT ALUMINUM OR POLYPROPYLENE
PLUNGER ............................................... CERAMIC
VALVES.................................... STAINLESS STEEL
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 personal injury, death or major property damage if
ignored.
___________________________________________________
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 that the 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.
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.
WARNING!
CAUTION!
CAUTION!
CAUTION!
CAUTION!
WARNING!
WARNING!

Pumptec Operating Instructions and Parts Manual Pump 112X-Series
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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 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 which provide a specific and constant
amount of fluid 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 the 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
regulator/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.
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.
CAUTION!

Pumptec Operating Instructions and Parts Manual Pump 112X-Series
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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.
• A low-pressure, flexible hose should be used between the
bypass connection and 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 the system.
USING CHEMICALS
Chemicals can be mixed into the fluid, but 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 in 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 the chemical
-Chemical injection rate can be controlled
-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
PEST SPRAYING
This application can have specific chemical usage requirements
and 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 the 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.
DO NOT return bypass fluids from regulator valve directly back
to the inlet of the 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 fluid can
heat up rapidly and lead to further cavitation and component
damage. It is recommended to route a bypass line back to the
inlet of a filter to allow air bubbles to dissolve and water to cool
prior to re-entering the 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 needs 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, two pieces of ’02 nozzle equals the performance of
one piece of ’04 nozzle.
Nozzles create restriction (pressure) in the system. If unsure of
the nozzle size needed for desired performance, refer to the
Nozzle Performance Chart. If you are sure of your nozzle size,
but unsure of which pump set to choose, use the Nozzle
Performance Chart along with the Horsepower Chart to
determine your required pump specification. See next page.
STORING
For extended storage times or between uses in cold climates,
drain all 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 with

Pumptec Operating Instructions and Parts Manual Pump 112X-Series
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every seal change. Duty cycle, temperature, quality of pumped
liquid, and inlet feed conditions all affect the life of a pump’s
parts and service cycle.
NOTE: Remember to service the regulator/unloader at each
seal servicing and check all system accessories and connections
before resuming operation.
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

Pumptec Operating Instructions and Parts Manual Pump 112X-Series
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MAINTENANCE
DISASSEMBLY AND REASSEMBLY (112X VIDEO)
1. Remove pump from motor using hex wrench. Remove
bolts from pump.
Figure 1
2. Holding each head, pull them apart to remove plunger.
Remove retaining plate from pump head. Remove internal
seal parts with finger. Discard parts but keep head and
retaining plate.
Figure 2
3. Clean head with rag or towel. Inspect for damage or
excess corrosion. If the head is damaged, do not rebuild.
4. Fit o-ring around seal ring and gently place in seal bore
with both thumbs. Place plunger guide into seal bore, level
about the o-ring/seal combo. Apply even pressure to
install plunger guide into seal bore. See Fig. 3.
Figure 3
5. If the plunger guide is not flush with seal bore opening,
remove guide, and verify that the o-ring and seal are
properly installed without bulges/creases. Slide retaining
plate into place.
Figure 4
6. Repeat previous steps 3-5 with the other head.
7. Lightly grease plunger ends with the clear grease
provided. Slide plunger into one head assembly and then
slide the other head onto plunger. Position assembly with
valve pockets facing up.
Figure 5

Pumptec Operating Instructions and Parts Manual Pump 112X-Series
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8. Adjust plunger slot position towards center and have slot
facing work surface. Replace all valves, o-rings, and white
washers. Refer to video and figures for proper orientation.
IMPORTANT:It is imperative the alignment of OUT/IN
ports coincide with valves as indicated in Figure 7.
Figure 6
Figure 7
9. Place manifold on top of plunger/head assembly. It may
be necessary to move heads on plunger to have valves
align with valve pockets on manifold. Be careful not to lose
the white washers on manifold during reassembly. You
may hear a click when everything is aligned.
10. Turn assembly over and place SS bolts/washers into heads
and tighten finger tight. DO NOT tighten completely at this
time.
Figure 8
11. Apply Super Lube®multi-purpose grease from suppled
packet into corners and center of plunger slot.
Figure 9
12. Mount pump back onto motor and tighten mounting bolts
to 14in/lbs or torque. Tighten head bolts to 14 in/lbs of
torque.

Pumptec Operating Instructions and Parts Manual Pump 112X-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 112X-Series
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Repair Parts Illustration for Aluminum 112X Pump
EXPLODED VIEW IMAGE
REPAIR PARTS LIST FOR 112X PUMP
DESCRIPTION
PART NO.
CONTENTS
KIT-A
10104
Viton o-rings, seal ring, plunger guide, and small grease packet
*Plunger and retainer plates not included.
KIT-B
10008
Viton o-rings, check valves, plastic washers, and small grease packet
*Not SS bolt/washer

Pumptec Operating Instructions and Parts Manual Pump 112X-Series
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Repair Parts Illustration for Polypropylene 112X Pump
EXPLODED VIEW IMAGE
REPAIR PARTS LIST FOR 112X PUMP
DESCRIPTION
PART NO.
CONTENTS
KIT-A
10104
Viton o-rings, seal ring, plunger guide, and small grease packet
*Plunger and retainer plates not included.
KIT-B
10117
Viton o-rings, check valves, and small grease packet
REG. KIT
10118
Viton o-rings, polypropylene plunger, and small grease packet

Pumptec Operating Instructions and Parts Manual Pump 112X-Series
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ADDITIONAL RESOURCES
Pumptec Returns Authorization Request Form
Warranty Policy
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 visit Pumptec's
website, email, or call Pumptec. Pumptec will give additional directions. If unable to resolve satisfactorily, write to Pumptec at the
address below, giving the 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.
Phone: [phone]