There are a number of factors which may have a marginal impact on flow rate. Some if these I have covered in an article ( link )
http://www.springltd.co/node/138Combine them and you may see a slight variance even if every thing is almost identical. Differences in flow between two pumps is not unusual.
Each pump will be slightly different in its water production, equally the hose wall of each line will expand at a slightly different rate. Pressure is created in the system by the pump and hose primarily and over the 110 + run we would expect to see a differential.
Some pumps are more efficient. In some recent testing we found that some pumps built pressure quicker than others and had a better current draw when compared. Some push fit connectors on the pump port can effect pressure and flow. For example Some pumps produce more flow at a lower setting. So a flow setting of 30 may give the same flow as 40 on a different pump
As with any pump, controller calibration is the key. Calibration tells the control what the base operating pressure of the system is . When flow is stopped the calibration setting will effect how long the control takes to DE the pump The higher the calibration the longer it tales to DE the pump. In turn the higher the pressure in the system.
Factors to take into account is hose wall resistance and any resistance created in the system by connectors, changes in hose size, angle adaptors at sharp angles. These all have an impact on flow In effect any of these can create back pressure slowing the flow. In some cases increasing pressure will not increase flow due to the back pressure. You simply end up with very fast moving water.
I noted your test involved a open hose with no jets, even here the run of hose will create some back pressure and restrict the flow.
Looking at your table Pump 1 at flow 40 took 190 second to fill 5 litres. Pump 2 at flow 60 took 188 seconds. To answer your question re current, running pump 2 at 60 would draw approx 0.5 of an amp more.
rush
Pump 1 at 40 will be drawing up to about 2 to 2.5 amps an hour, Pump 2 at a flow of 60 will draw around 3 to 3.5 amps. so the combined current would not likely be more than 6 amps an hour.
Although you would likely find that once you have your brush and jets attached the difference in flow rates would be less as the jets will create pressure.
Although a sharply angled adaptor would effect this as the pump may have to work harder to over come the restriction. Remember a restriction will also increase back pressure and in turn effect flow.