OPERATING INSTRUCTIONS

TWO STAGE, HI-LOW

EXTERNAL GEAR
HYDRAULIC PUMPS
MODELS 1012, 1053 AND 1056
BARNES OIPM P/N_________________
2690165
READ CAREFULLY BEFORE ATTEMPTING TO ASSEMBLE, INSTALL, OPERATE OR MAINTAIN THE PRODUCT DESCRIBED.
PROTECT YOURSELF AND OTHERS BY OBSERVING ALL SAFETY INFORMATION. FAILURE TO COMPLY WITH INSTRUC-
TIONS COULD RESULT IN PERSONAL INJURY AND/OR PROPERTY DAMAGE!
RETAIN INSTRUCTIONS FOR FUTURE REFERENCE.

Description
Our two stage, hi-low, external gear hydraulic pumps, Models
1012, 1053 and 1056, are designed to be direct-driven by gas
engines or electric motors. They are suited for use in log split-
ters and other applications, such as: hydraulic lifts, platform
lifts, die tables, automatic hoists, trash compactors, bench
presses, machine tool lube systems, filter systems, clamping
devices, and transfer systems, etc. They are ideal for press-
type applications requiring fast approach/retract speeds and
slower peak actuator work speeds because of horsepower lim- Figure 1
itations or safety constraints.

Unpacking
Due to cast iron construction, very little damage can occur dur- A
B
ing transit. Do not remove the plastic shipping plugs from the C .12 .5000
.4997
ports until ready for installation. This will keep dirt or foreign TWO STAGE “HI-LO”
.62
material from entering the system. 1.7815
GEAR PUMP

1.7800
.56
*See Specification section to determine drive key type and
size. 1.50
INLET PORT SEE PARTS LIST
Specifications
OPPOSITE 1/2-14 HYDRAULIC SCHEMATIC
Stages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 NPTF OUTLET PORT
3.00
Max. Operating Speed . . . . . . . . . . . . . . . . . . . . . 3600 RPM 2.560 2.144
1.750 1.750
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast Iron
1.000 1.000
Max. Operating Pressure . . . . . . . . . . . . . . . . . . . . 3000 PSI
1.406
Unload Valve Setting . . . . . . . . . . . . . . . . . . . . . SEE CHART
1.000
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Bolt 4F17 2.812
1.000
Shaft Extension . . . . . . . . . . . . . . . . . . . . . . . . . . 11/2" (1.50")
Shaft Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2" (.50") .344 DIA. THRU
1.406 MOUNTING
Keyed Shaft . . . . . . . . . . . . . . . Model 1012 – #404 Woodruff 2.812 HOLES (4)
Models 1053 & 1056 – .12 square x 1.0" Figure 2 - Dimensions
Inlet Port . . . . . . . . . . . . Model 1012 3/4”, Others 1" dia. tube
Performance Characteristics*
Outlet Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2-14 NPTF
MODEL
Pump Rotation . . . . . . . . . . . . . . . . Clockwise (Facing Shaft) 1012 1053 1056
1st Stage .517 .647 .766
Minimal Displ.
SEAL KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P/N 2300260 (cu. in./rev.) 2nd Stage .129 .194 .258
Total .646 .841 1.024
GPM @ 1st Stage 8.06 10.08 11.94
3600 RPM 2nd Stage 3.02 3.02 3.97
@ 250 PSI Total 10.07 13.1 15.91
CAUTION 1st Stage 500 500 600
Max. Pressure
These pumps are built for clockwise rotation as viewed PSI 2nd Stage 3000 3000 3000
from the shaft end of the pump. Gas engine or electric
Min. HP @ 2000 PSI 5 HP 5 HP 8 HP
motor must turn the appropriate direction to avoid damage
(3500 RPM)
to the pump assembly.
(*) When outlet port pressure is under 450 PSI, both stages are
working and total displacement applies. Above 450 PSI, only
2nd stage displacement applies.
 MODELS 1012, 1053 AND 1056

Specifications (Continued) Installation

2-Stage, High/Low Pump Dimensions (Tabular)

MODEL A B C
CAUTION
Do not overtighten fittings and bolts – this can damage the
1012 4.906" 4.031" 2.531" pump.
1053 5.468" 4.594" 3.094" 1. Assemble one coupling half to the engine/motor and tight-
en the set screw.
1056 5.468" 4.594" 3.094" 2. Assemble the other coupling half loosely to the pump shaft.
Note drive key dimensions in Specification section of this
manual.
WARNING!
CAUTION
General Safety Information
DISCONNECT POWER BEFORE SERVICING THIS EQUIPMENT. Do not force coupling onto pump shaft. A snap ring inside
pump may be damaged by forcing coupling.
1. Follow all local electrical and safety codes, as well as the 3. Insert the rubber spider into engine/motor coupling half.
National Electrical Code (NEC) and the Occupational
Safety and Health Act (OSHA). 4. Bolt the pump and mounting gasket “A” loosely to 4-bolt
foot-mounted pump adaptor.
2. Never exceed the maximum operating speed and pressure
5. Align the shafts to make sure they are on center with each
of the pump.
other.
3. If using AC motors, ground the motor properly by wiring
with a grounded, metal-clad raceway system, using a sep-
arate ground wire connected to bare metal of the motor
CAUTION
frame, or other suitable means. Misalignment with shafts may result in premature shaft
4. Guard all moving parts. seal failure.
6. Tighten the mounting bolts.
WARNING! 7. Mate the coupling halves together, allowing 1/16" gap
between halves.
RELEASE SYSTEM PRESSURE BEFORE SERVICING THIS 8. Check shaft alignment again.
EQUIPMENT.
5. Drain all liquids from the system before servicing. CAUTION
6. Check hoses and connections for security before each use. The gap in the coupling halves is to prevent end loading of
7. Periodically check the pump and system components. the pump shaft.
8. Provide a means of pressure relief for pumps whose dis- 9. Tighten the set screw in the pump coupling half.
charge line can be shut off or obstructed. 10. Remove plastic port protectors from the inlet and outlet
9. Wear safety glasses at all times when working with pumps. ports.
10. Keep work area clean, uncluttered and properly lighted; 11. Squirt oil into the pump for pre-lubrication for start-up.
replace all unused tools and equipment. 12. Turn shaft coupling slowly to ensure proper shaft alignment
11. Keep visitors at a safe distance from the work area. and coupling installation.
12. Make the workshop child-proof with padlocks, master 13. Connect inlet line by slipping inlet hose over inlet tube and
switches, and by removing starter keys. fasten with hose clamp.
13. Do not operate an engine in an enclosed area. NOTE: A few drops of oil on inlet tube beaded section will
help ease the installation.
14. Do not spill gasoline on hot engine surfaces.
14. Keep inlet hose short and of adequate size to avoid pump
15. Store gasoline only in an approved container. cavitation.
16. Keep dirty and oily cleaning rags in a tightly closed metal NOTE: Cavitation is recognized by excessive pump noise.
container.
17. Check engine oil level before operating the engine.
18. Familiarize yourself with the controls and emergency shut-
CAUTION
down procedures. Provide cooling for the hydraulic oil based on: duty cycle,
pressure/flow, ambient temperature, oil and component
19. Never operate the equipment when you are fatigued. maximum temperature specifications, and reservoir
20. All system components pressure ratings should be greater capacity.
than maximum system pressure. 15. Use a 1/2" NPTF, high pressure fitting for the outlet port.
21. Put safety guards on all moving parts. Use a good quality pipe joint compound (pipe dope) on all
22. Keep all guards in place. NPTF hydraulic fittings.

CAUTION
Flush all lines to ensure contaminants have been removed.

–2–
 MODELS 1012, 1053 AND 1056

Installation (Continued) 3. The unloading valve is adjustable up to 600 PSI by turning

the adjusting screw clockwise.
CAUTION
Do not use Teflon tape on NPTF hydraulic fittings. CAUTION
CAUTION Pressure gauge required when adjusting unload valve.
NOTE: Increasing the unloading valve pressure will require
Do not overtighten NPTF pressure fitting in pump. This
increasing the pump drive horsepower. Factory preset, with a
could distort or crack the pump gear housing.
400-900 PSI adjustment range. Maximum recommended load-
ing for 3 HP electric motors and 5 HP engines is 550 PSI.
CAUTION
Never run pump without hydraulic oil. CAUTION
16. At initial start-up, turn the pump several times by hand to If pump has not operated for an extended period of time,
prime the pump. manually rotate pump shaft to prime and lubricate pump.
17. Bleed all air from the system to prevent erratic pump operation.
18. After several cycles, check the reservoir oil level and refill
Maintenance
as necessary. 1. Keep the reservoir filled with hydraulic fluid.
NOTE: When the ambient temperature is below 32°F, allow the NOTE: Use a good quality automatic transmission fluid
pump to operate at low pressure for several minutes to warm (ATF) for year round operation.
the oil in the reservoir. 2. Make frequent inspections of hydraulic oil and change if
contaminated.
Operation
3. To fill the reservoir with clean oil. Use a clean funnel fitted
1. Check oil level before each use.
with a fine mesh wire screen. Do not use a cloth strainer.
2. Follow operating instructions for engine or motor. Most pump failures, valve malfunctions, and short unit life
can be traced directly or indirectly to dirt or other foreign
WARNING! material (water, chips, lint, etc.) entering or already in the
hydraulic system.
DO NOT EXCEED THE PRESSURE RATINGS OF THE SYS- 4. Keep the unit clean of dirt and foreign materials.
TEM COMPONENTS. A HYDRAULIC PRESSURE GAUGE IS
5. Keep electrical connections clean.
RECOMMENDED IN THE HYDRAULIC CIRCUIT.

Troubleshooting Chart
SYMPTOM POSSIBLE CAUSE(S) CORRECTIVE ACTION
Pump does not develop full 1. System relief valve set too low or leaking 1. Check system relief valve for proper set-
pressure ting with pressure gauge in outlet line
2. Oil temp. is too high 2. Let oil cool below 140°F
3. Pump is worn out 3. Replace worn parts or pump
4. Double acting cylinder piston seals are cut 4. Replace or repair cylinder
or worn out

Motor won’t start 1. Loose connection 1. Check wiring

2. Circuit breaker tripped 2. Reset circuit breaker
3. Voltage drop 3. Use heavier gauge wire
4. Seized pump 4. Replace pump

Will not pump oil (Motor 1. No oil in reservoir 1. Check oil level, refill
runs but cylinder does not 2. Motor operating wrong rotation 2. Change rotation of prime mover
move, or moves slowly) 3. Oil level low 3. Add oil as needed
4. Suction strainer is clogged 4. Clean suction strainer
5. Double acting cylinder piston seals are cut 5. Replace or repair cylinder
or worn out
6. Reservoir breather is dirty or clogged 6. Clean reservoir breather and reinstall

Pump motor unit is noisy 1. Low oil level 1. Add oil as needed
2. Air in system 2. Bleed air from highest fitting in system
by loosening fitting very slightly and
operating unit until bubbling of air
stops, then tighten
3. Suction strainer or in-line filter is clogged 3. Clean suction strainer or in-line filter

–3–
 MODELS 1012, 1053 AND 1056
3 5 6 1 4 2

19 17 18 24
20 16

15

22 23
14 13 12 1011 8 9 7 21
Replacement Parts List
REF. PART NUMBER FOR MODEL:
NO. DESCRIPTION 1012 1053 1056 QTY.

1 Dowel pin 2230031 2230031 2230031 1

2 Plunger 2160206 2160206 2160206 1
3 Copper gasket 2260001 2260001 2260001 1
4 Spring 2110003 2110003 2110003 1
5 Adjustment screw 2130024 2130024 2130024 1

6 Hex cap nut (torqued to 15 # ft.) 2140008 2140008 2140008 1

7 O-ring 2120024 2120024 2120024 1
8 Ball 2870008 2870008 2870008 1
9 O-ring 2120078 2120078 2120078 1
10 Cap 2420088 2420088 2420088 1

11 Spring 2110051 2110051 2110051 1

12 O-ring 2120019 2120019 2120019 1
13 Hex plug 2420106 2420106 2420106 1
14 Valve stem 2160009 2160009 2160009 1

15 Drive shaft 2350177 2350678 2350679 1

16 Drive key 2250013 2250011 2250011 1
17 Gear key 2250013 2250013 2250013 1
18 Snap ring 0.50 2240013 2240013 2240013 4
19 Gear key 2250020 2250020 2250013 1

20 † Assembly screws (1/4-20) 2130078 2130080 2130080 8

21 ‡ Gasket kit 2300480 2300480 2300480 1
22 Drive pin 2230021 2230021 2230021 1
23 ‡ Gasket kit 2300481 2300481 2300481 1
24 Shaft seal 2120104 2120104 2120104 1

Required for mounting

D 5/16-18 x 3/4 Grade 5 mounting bolts 2130107 2130107 2130107 4
D 4-Bolt mounting gasket 2260064 2260064 2260064 1
D 5/16 Lockwasher for mounting bolts 2150042 2150042 2150042 4
† Screws for item #20 (Grade 8 socket head screws are acceptable)
‡ Gaskets are color coded to maintain specific gear clearances in pump
D Not shown –4–