INFORMATION TROUBLESHOOTING GUIDE
Contents
1. nn nnn nenn 1 TIPS OM ROPAS een OHMIMeter 4 2 22 e 1 Assorted Hoses High Pressure Fittings 1 een tence High Pressure Shutoff Valve 1 D C Hydraulic Models Hydraulic Fluid 22444444 44444 1 Part Sheets Available from Monarch The Purpose of Oil 1 2 Selecting Fluids for Applications Outside of ATF s Temperature Range 2 Pump Priming serpii nennen nennen 2 New Installations 2 On Systems That Fail to Prime or Lose Their Prime Check for the Following 2 3 amp 3 Use Recommended Fluid 3 Correct Filling and Operating Procedure 3 Problems Associated with The Reservoir 3 4 Tips and Comment 4 4 Suction Filters 4 Additional Filter Systems 4 5 Electrical 5 LOW Vollage ns 5 8 D C Motors Wound Field 6 D C Motors Permanent Magnet 6 Electrical Switches 7 8 Shorts Grounding Faults and Open GCUI serieei aa A 8 Solenoid Coll 8 Electric2. 2 The valve ground wire See section on Open Circuits 3 The switch controlling the valve See section on Electrical Switches 4 Low Voltage See section on Low Voltage 5 The solenoid coil See section on Sole noid Coils 6 Dirtin the valve cartridge This can be 7 5 2 WAY 2 POSITION VALVE amp COIL FIG 13 done by energizing the valve without starting the motor and listening for the valve to shift a definite Click is heard when the valve in energized If the valve does not shift remove the cartridge from the valve body Blow compressed air through the cartridge in both directions while holding the plunger off its seat use a blunt object inserted through bottom of cartridge It will help to have the body filter removed A bent valve stem Replace valve NOTE The cartridge itself cannot be disassembled in the field as the proper tolerances cannot be duplicated If the dirt cannot be removed the cartridge will have to be replaced Monarch Hydraulics Inc 13 B Ifthe valve does not return to the neutral or unshifted position check for dirt in the valve cartridge or a bent stem 2 3 WAY 2 POSITION AND 4 WAY 2 POSITION VALVES Troubleshoot and Repair As Follows See Fig 14 and Fig 15 3 WAY 2 POSITION VALVE amp COIL SHOWN WITH MANUAL OVER RIDE OPTION FIG 14 Ifthe valve does not shift check for and repair the following 1 The valve
3. and constructed as follows 1 One large post must be attached to the cable leading from the battery Battery 2 The small post connects to the Terminal I control circuit Push button rocker Zu switch or toggle etc 3 The shared hot lead from the control circuit must also be attached Insulated Can to the large post from the battery Monarch Hydraulics Inc 7 4 The remaining large post attaches to the cable leading from the motor 3 4 Post Solenoid Switch Fig 3 Isolated Ground Isolated Ground a The four post solenoid switch is wired and constructed as follows 1 One large switch post is connected to the battery cable either one 2 The remaining large post is con nected to the motor cable 3 The 2 small posts are connected to the coil one post to each end 4 With access to both ends of the coil the specific wiring arrangements can be varied but to energize the coil one lead has to be positive and the other end negative b Testing for a faulty solenoid switch When testing use an OHM meter conti nuity light or test light and check all functions as described above See Test Equipment Section 5 SHORTS GROUNDING FAULTS AND OPEN CIRCUITS In control wiring shorts can only occur when hot lines lines connected directly to the battery come in contact with ground A short will either cause a fuse to blow if there is one or burn the wi
4. The valves are normally installed in the return portion of a hydraulic circuit They maintain a more constant flow even if the pressure is changing They are made by matching an orifice to a special spring so they can meter flow Troubleshoot and Repair as Follows See Fig 16 PRESSURE COMP FLOW DIRECTION q PRESSURE COMPENSATED ORIFICE FIG 16 If flow is blocked it could be because a particle of dirt has covered the orifice hole in the piston It could also be caused by a piston that has over travelled the return ports in the side of the housing and has become jammed in contamination at the bottom of the cavity The inner housing and piston can be removed as an assembly Inspect orifice hole for dirt and blow compressed air through side holes to dislodge contamination Push on inner piston with a blunt object and observe the piston moving past side holes in the housing If it is smooth it is working properly If it is sticky remove push clip and disassemble Clean with solvent and compressed air oil the parts and reassemble Do not use emery paper or steel wool to polish parts or touch orifice with a pick or drill bit compressed air only Replace as an assem bly if it does not work properly Adjustable Flow Control This valve has a needle to adjust oil flow in the direction of the arrow It has an internal check valve so reverse flow opposite the arrow is unaffected by the
5. hot wire See section on Open Circuits 14 4 WAY 2 POSITION VALVE amp COIL FIG 15 The valve ground wire See section on Open Circuits The switch controlling the valves See section on Electrical Switches Low Voltage See section on Low Volt age The Solenoid Coil See section on Solenoid Coils Dirt in the valve cartridge This can be done by energizing the valve without starting the motor and listening for the valve shift If it cannot be heard remove the cartridge from the valve body and blow compressed air through all parts to dislodge dirt Clean all parts in solvent blow dry and lubricate B Ifthe valve does not return to the neutral or unshifted position check for dirt in the valve cartridge and repair in the same manner as above 3 SPECIALTY VALVES A Cartridge Style Check Valves These valves screw into a cartridge cavity and allow for free flow from the end to the side and block reverse flow See Fig 12 Troubleshoot and Repair as Follows If the valve does not hold remove the cartridgefrom the housing Blow compressed air through the cartridge from the side to the bottom while holding the ball or poppet off the seat use a blunt object inserted through the bottom of the cartridge to hold the poppet off the seat NOTE The valve itself cannot be disassembled in the field replace it if cleaning does not the problem B Pressure Compensated Orifice
6. 8 D Lowering Valve 3 Suction Filter 8 E Cartridge Check 4 Motor Start Solenoid Battery Post 8 F Lowering Valve 5 Fill Vent Plug 8 G Selector Valve 6 Check Valves 8 H 2 Way 2 Position Valve 6 7 Port Filter Locations 8 J 4 Way 2 Position Valve 8 K 3 Way 2 Position Valve OUTLET PORT 3 8 NPT REF gt 3 boy 91 SHOWN WITH OPTIONAL MOTOR START SOLENOID SWITCH AND STRAP OUTLET PORT 3 8 NPT REF pa 20 TO BATTERY wll Lesh amp OUTLET PORT En ACKET 2 2 1 P C2PORTRV wie a1 go 1 COS ZT MWg 7 SHOWN WITH OPTIONAL i AZ MOUNTING BRACKET 4 i 1 1 RV EG i Monarch Hydraulics Inc 21 Typical Location of Basic Parts 1 Relief Valve 2 Port Outlets 2 A 3 8 Pipe High Pressure 2 B 1 4 Pipe High Pressure 3 Suction Filter 4 Motor Start Solenoid Battery Post 5 Fill Vent Plug 6 Check Valves 7 Port Filter Locations 8 Valves 9 Specialty Valves 8 A Lowering Valve 9 A Pressure Compensated Orifice 8 B Port Relief 9 B Adjustable Flow Control 8 C Lowering Valve 8 D Lowering Va
7. Fig 4 amp 5 In style shown in Fig 4 loosen jam nut In style shown in Fig 5 remove flush plug NOTE When adjusting the relief valve be sure to use a pressure gauge and consult with the manu facturer for the proper pressure setting Failure to accurately set the relief valve can cause failure resulting in damage to the equipment or cause bodily harm B Relief Valve Pressure Too Low 1 Symptoms a Motor RPM is faster than normal b Cylinder will not extend c Excessive turbulence in the reservoir Note On applications where the cylinder is being replaced or the mechanical mechanism is being modified make sure the pressure capability of the pump is not being exceeded 2 Repair Procedure a There are 2 possible causes for lack of Pressure 1 The adjusting screw has backed 2 Foreign matter dirt is trapped between the seat and the ball or cone b Repair as follows 1 Using a gauge tee d into the pressure line loosen the jam nut and turn the adjusting screw clockwise a turn or two and watch the gauge ifit goes up continue to turn the screw until the required setting is reached Retighten the jam nut In the Old Style relief if the screw does not remain in the correct position use one with a patch In an emergency the screw threads can be deformed slightly with a small prick punch and hammer S If the pressure does not increase when the adjusting screw is tightened tu
8. for troubleshooting problems that are related to low voltage They are used in two ways first one probe is grounded while the other is used to probe the HOT leads the meter shows the voltage available at the point where the second probe is connected second they can be used to measure a voltage drop in a wire one probe is connected to one end and the remaining to the other end the reading is the voltage drop 5 OHM METER An ohm meter is used to measure resistance and is a very useful tool when working on wire circuits and solenoid coils On some coils the wire resistance is up to a level where a D C test light might show an open circuit and it really is not so An infinite meter reading on any test shows that the circuit is open A coil test however will always show some value of resistance but it must not be infinite All tests conducted with an ohm meter must be done with the battery disconnected from the system 6 ASSORTED HOSES HIGH PRESSURE FITTINGS These can be used to connect and or isolate certain parts of a hydraulic circuit to a pressure gauge or a shutoff valve for diagnosing hydraulic problems 1 4 NPT and 3 8 NPT are the most commonly used sizes 7 HIGH PRESSURE SHUTOFF VALVE The shutoff valve can be used to choke off oil flow so that a false load can be put on the pump and other components With the valve installed it can be slowly shut off while the equipment listed above records the data for
9. needle Troubleshoot and Repair as Follows See Fig 17 CONTROLLED FLOW DIREC TION lt _ _ Fy 1 44 Le ioe nt F gt CONTROLLED FLOW ADJUSTABLE FLOW CONTROL VALVE FIG 17 Open needle by loosening the jam nut on the stem and turn the stem out Inspect for dirt in ports and remove if possible Blow com Monarch Hydraulics Inc 15 16 pressed air through valve first against the arrow and then with the arrow Turn needle to full closed position do not jam on seat or perma nent damage could result If compressed air is blown against the direction of the arrow it will pass through the valve freely if compressed air is blown in the direction of the arrow it will be blocked or almost blocked If this is not true replace the valve make sure the arrow points in the proper direction Adjustable Needle Valve This valve has a needle to adjust oil flow It affects flow in either direction Troubleshoot and Repair as Follows Open needle by loosening the jam nut on the stem and turn the stem out Inspect for dirt in ports and remove if possible Blow com pressed air through valve Turn needle to full closed position do not jam on seat or perma nent damage could result Blow compressed air into one port and check to see if it is blocked from exiting the other Replace if dirt cannot be removed Inline External Relief Valve Port Relief This valve is made up of a hous
10. E VALY SPRINGS 3 E dei CROSS CHECK WITH MANUAL OVERRIDE SCREW ACTUATOR STYLE SHOWN ALSO AVAILABLE WITH PLUNGER FIG 21 DOUBLE PILOT OPERATED CHECK FIG 20 H Double Cross Over Relief Valves There are two styles used One style is made up of a loose ball spring screw seal and jam nut Clean as described in Relief Valve section 2 The other is a cartridge relief See Relief Valve section 2 B for cleaning instructions Lowering Valves Manual lowering valves are used in power up gravity down circuits as either a primary lowering device using a plunger or as a back up device using a screw They are made using a ball and spring with an actuator to dis lodge M 311 LOWERING VALVE the ball They can be repaired like internal check valves See Check Valve Section on ball FIG 22 valves See Fig 11 and Fig 21 amp 22 Monarch Hydraulics Inc 17 TIPS ON REPAIRS 1 Do not screw cartridge valves into cavity too fast use a back and forth motion and have O rings well lubricated 2 Clean all parts thoroughly before assembly and lubricate with clean oil 3 Do not use Teflon tape on hydraulic connec tions as it can easily jam the valves and plug the filters in the system 4 Use care when working on electrical compo nents to prevent shorts ground faults and open circuits 5 Remove all rings watches and jewelry that might co
11. ISE TO INCREASE PRESSURE 2 TURN SCREW COUNTER CLOCKWISE TO DECREASE PRESSURE 2 NOTE OUTLET PORT FLOW MUST BE BLOCKED TO MAKE RELIEF VALVE OPERATE WHILE ADJUSTING 4 REINSTALL FLUSH PLUG 1 OLD STYLE RELIEF B Keep the amp draw and battery drain ata An internal cavity is drilled into the pump base minimum when the cylinder dead heads into which the following parts are inserted to reaches full stroke make up the relief valve assembly 2 THE TWO STYLES OF RELIEF VALVES USED a Ball or cone heavy spring and in some BY MONARCH ARE cases a jam nut and seal washer A Loose Component Style B Cartridge Style See Fig 6 1 Internal Cavity with Loose Components A complete cartridge is assembled into an See Fig 4 amp 5 intregal cavity Monarch Hydraulics Inc 9 10 CARTRIDGE RELIEF VALVE FIG 6 3 DIAGNOSING AND REPAIRING RELIEF VALVES NOTE When testing or making adjustments on the relief valve the system must be dead headed cylinder at full stroke or in a position where cylin der movement is zero A Relief Valve Pressure Too High 1 Symptoms a Amp draw and battery drain excessive when system is dead headed b Motor RPM is slow in comparison to full load system operation 2 Repair Procedure a Turn relief valve adjusting screw coun terclockwise using a gauge tee d into the high pressure line to record the proper pressure setting See
12. MONARCH M Series D C HYDRAULIC POWER UNITS The No 1 Problem with a unit not working at all is that the threaded ground GND has not been connected to an adequate ground with a cable at least as large as the supply cable size Painted or powder coated parts are insulators Grounds must be to bare metal For the most up to date version of this guide Please visit our website www monarchhyd com General Information THIS GUIDE IS MADE AVAILABLE TO YOU BY MONARCH HYDRAULICS INC PLEASE Before Calling MONARCH be certain that P O Box 1764 Grand Rapids MI 49501 1764 U S A 1363 Michigan St NE Grand Rapids MI 49503 U S A Telephone 616 458 1306 Telefax 616 458 1616 e mail monarch iserv net 2 You have the following information available http www monarchhyd com a Model Number b Serial Number IMPORTANT 1 You have read the guide carefully and are certain that all ofthe possible causes pertaining to your problem have been reviewed DO NOT VOID YOUR WARRANTY This guide carries many useful tips for troubleshooting your hydraulic power unit It should be noted however that any disassembly of a power unit that is still under warranty will void that warranty If you need any assistance contact the factory Always wear eye protection and protective clothing when working on and around hydraulic systems Remove jewelry and objects that might conduct electricity while working on power unit
13. PACK CORPORATION A Part of the Monarch Hydraulics Group 460 Newbold St London Ontario Canada N6E 1K3 Telephone 519 686 5900 Telefax 519 686 8976 Litho in U S A
14. al Polarity 8 Relief VaN ES seinasta aona ni 8 The Purpose of a Relief is to 8 The Two Styles of Relief Valves Used by Monarch are 9 10 Diagnosing and Repairing Relief Valves 10 11 Check Valves cnsesseensnnnnnnnenennnnnnennnn nen 11 Purpose of a Check Valve 11 Three Types of Check Valves are Used 11 12 Troubleshooting and Repairing Check Valve 12 Monarch Hydraulics Inc i Maintenance and Troubleshooting Guide for Monarch D C Hydraulic Power Units Always wear eye protection and protective clothing when working on and around hydraulic systems Remove jewelry and objects that might conduct electricity while working on power units Hydraulic fluid does pose a fire harard can cause burning or skin irritation if not properly handled Fluid under pressure can pierce the skin and enter the bloodstream causing death or serious injury Devices being operated by the hydraulic system should be immobilized so they cannot move and cause injury while being inspected or repaired Disconnect from electrical source Prior to performing any maintenance make sure the equipment is turned off and that any stored energy for example pressure is released Also extended equipment or cylinders should be lowered and mechanically locked as required Mon
15. arch Hydraulics is not responsible for misuse or misapplication of product If you have any questions about application please concact local dealer Fluids should be contained and disposed of prop erly NOTE Do not use Teflon tape on hydraulic fittings as it can easily jam valves and plug the filters in the system TEST EQUIPMENT The following is a list of the test equipment required to troubleshoot D C powered hydraulic systems 1 PRESSURE GAUGE A small 0 5000 Pressure gauge preferable glycerin filled is avery valuable and relatively inexpensive tool for checking pressure in the various sections of the circuit 2 D C TEST LIGHT A test light is simply a light bulb which has one end connected by a wire to an alligator clip and the other end connected to a metal probe It is used to check the electrical circuit when the battery is connected to the system The alligator clip is grounded and the light glows when the probe comes in contact with a HOT electrical component They are easily obtained from automotive jobbers or discount stores 3 CONTINUITY LIGHT A continuity light is like a test light but contains its own battery power source It is used for testing electrical circuits when the components are not connected to a battery They are easily obtained from discount stores or electrical jobbers at modest cost 4 VOLT METER AD C volt meter as used in the automotive repair business is a good investment
16. asure the depth of the retainer so it can FIG 10 be reassembled to the same depth after repair b Remove spring c Remove ball or follower and ball d Start pump to flush dirt from the seat area Caution divert oil into a con tainer Do not look into the port Inspect the ball for damage and replace if necessary f Reinstall ball or ball and follower RETURN g Seat the ball using a small drift punch FLOW and hammer with a light tap gt h Reinstall the spring i Replace the spring retainer to the correct depth 3 Repair Procedure Cartridge a Remove cartridge and clean or replace See Specialty Valve Section A M 313 MAIN POPPET CHECK AND LOWERING VALVE B Blocked Flow Failure 1 Symptom Once in a while a ball type check valve will restrict flow to the point where the spring will collapse and the flow will be greatly reduced even blocked causing flow over FIG 11 C Cartridge Type relief A Cartridge Type Check Valve is made up of a 2 Repair Procedure Loose Parts Design ball or poppet in a completely contained car a Remove the check valve components tridge See Fig 12 and replace the spring b Ifthe problem persists replace the ball type with a poppet type as they cannot completely block flow c Adjust screw to proper depth 3 Repair Procedure Cartridge a Replace cartridge See Specialty Valve Section A CARTRIDGE CHECK VALVE FIG 12 12 Alw
17. away from the area between the armature and the motor case when re installing the armature in order to avoid injury wiring diagram guide for D C power units is also available Request form 2347 99 THE MAGNETS WILL PULL THE ARMATURE INTO THE MOTOR UPON REINSERTION 4 ELECTRICAL SWITCHES 1 3 Post Solenoid Switch Fig 1 Insulated Can As Pusi Buton Toggle and Rocker Types a The three post solenoid switch is wired Defective switches are a common cause of and constructed as follows electrical malfunction What seems to be a 1 The large post marked Bat must be serious system defect can often be caused attached to the cable leading from simply by a faulty switch especially where the the battery switch controls two functions that is start the 2 The small post connects to the motor and shift a valve In those cases one control circuit Contact finger half of the switch might be defective while the push button toggle switch etc other half operates correctly and the fault 3 The remaining large post appears to be with some other component attaches to the cable leading from the motor Troubleshooting can be done by any one of three methods Note Do not attach motor cable to post marked 1 Use a continuity light to test switch See Bat as solenoid will not operate properly Test Equipment 4 Internally the coil is constructed with 2 Usea circuit test light to test s
18. ays wear eye protection and protective clothing when working on and around hydraulic systems Remove jewelry and objects that might conduct electricity while working on power units Hydraulic fluid does pose a fire harard can cause burning or skin irritation if not properly handled Fluid under pressure can pierce the skin and enter the bloodstream causing death or serious injury Devices being operated by the hydraulic system should be immobilized so they cannot move and cause injury while being inspected or repaired Disconnect from electrical source Prior to performing any maintenance make sure the equipment is turned off and that any stored energy for example pressure is released Also extended equipment or cylinders should be lowered and mechanically locked as required Monarch Hydraulics is not responsible for misuse or misapplication of product If you have any questions about application please concact local dealer Fluids should be contained and disposed of prop erly DIRECTIONAL CONTROL AND SPECIALTY VALVES 1 2 WAY 2 POSITION NORMALLY CLOSED VALVES These valves allow for free flow in one direction from the bottom port to the side ports at all times and checked flow in the opposite direction until the solenoid coil is energized See Fig 13 Troubleshoot and repair as follows If the valve does not shift check for and repair the following 1 The valve hot wire See section on Open Circuits
19. e bloodstream causing death or serious injury Ball Follower i e Light Spring Devices being operated by the hydraulic system Spring Retainer should be immobilized so they cannot move and cause injury while being inspected or repaired Disconnect from electrical source Prior to performing any maintenance make sure the equipment is turned off and that any stored energy for example pressure is released Also extended equipment or cylinders should be lowered and mechanically locked as required Monarch Hydraulics is not responsible for misuse or misapplication of product If you have any questions about application please concact local dealer Fluids should be contained and disposed of prop erly POPPET CHECK FIG 8 CHECK VALVES 1 PURPOSE OF A CHECK VALVE To allow free flow in one direction but block reverse flow 2 THREE TYPES OF CHECK VALVES ARE USED A Ball Type A Ball Type Check Valve is made up of the following See Fig 7 Ball M 250 SERIES POPPET CHECK e Light Spring Spring Retainer FIG 9 Monarch Hydraulics Inc 11 3 TROUBLESHOOTING AND REPAIRING CHECK SCREW FLUSH TO 1 32 DEEP VALVE FAILURES FROM BOTTOM OF S FACE A Load Drift Failure 1 Symptom In most cases a check valve will fail such that the load will drift down when the unit is in the hold position 2 Repair Procedures Loose Parts Design a Remove the spring retainer M 3598 POPPET CHECK NOTE Me
20. e make sure the equipment is turned off and that any stored energy for example pressure is released Also extended equipment or cylinders should be lowered and mechanically locked as required Monarch Hydraulics is not responsible for misuse or misapplication of product If you have any questions about application please concact local dealer Fluids should be contained and disposed of prop erly ELECTRICAL PROBLEMS 1 The minimum voltage between the motor stud and ground is 9 0 volts at maximum load conditions 2 The minimum voltage between the valve solenoid power wire hot wire and ground is 9 1 2 volts at maximum load conditions C Causes for low voltage are 1 Battery capacity too small 2 Cable ends not electrically secure to battery cable 3 Battery cable size too small for load and length of run See Battery Cable Guide below Larger copper battery cable 1 0 or 00 may be required for cable lengths over 25 feet to keep performance from deteriorating 4 Ground cable size not equivalent or larger than the battery hotside cable 5 Bad joints where cable ends are bolted to battery motor solenoid start switch ground and etc 6 Burnt contacts on motor solenoid or start switch PLEASE REMOVE ALL RINGS WATCHES AND JEWELRY PRIOR TO DOING ANY ELECTRICAL D Check for low voltage as follows A volt meter will be required 1 On vehicles equipped with an alternator the voltage
21. ent is turned off and that any stored energy for example pressure is released Also extended equipment or cylinders should be lowered and mechanically locked as required Monarch Hydraulics is not responsible for misuse or misapplication of product If you have any questions about application please concact local dealer Fluids should be contained and disposed of prop erly RESERVOIRS 1 USE RECOMMENDED FLUID Fill reservoir with the approved fluid and refer to the Hydraulic Fluid Section 2 CORRECT FILLING AND OPERATING PROCEDURE A Operate unit several times starting with short cylinder strokes and increasing length with each successive stroke B Recheck oil level often and add as necessary to keep pump from picking up air C After system is completely bled check oil level in reservoir as described in owner s manual and install the filler oreather plug provided NOTE Do not use a solid plug or a fill cap without a filler breather element or damage will be caused to pump and or reservoir 3 PROBLEMS ASSOCIATED WITH THE RESERVOIR A Clear oil flowing out of the fill hole might indicate that the cylinder s rod was not in it s retracted position when the reservoir was filled B Foamy oil flowing out of the fill hole points to the following 1 Air is present in the system that is cylin ders and fluid lines The response usually is spongy and the cylinder moves with jerking mot
22. f cleaning 2 ADDITIONAL SYSTEM FILTERS A MODELS M 303 M 503 M 603 M 723 M 3593 These specific models have filters in addition to the pump suction filter for protecting the valve One is located inside the two piece hex fitting just ahead of the DR 2 way 2 position car tridge lowering valve inside the reservoir It can be taken apart for cleaning or replacing the filter element B Models in M 640 Series These models also are equipped with additional filters for protecting the solenoid valves First each port and C on the flat surface have acone shaped filter in the valve body They can be reached as follows 1 If the ports C and on the flat surface are not being used remove the flush 1 4 pipe plugs 2 Ifthe ports and on the flat surface are being used remove the hoses 3 Reach down into these ports with a 1 4 allen key and remove the filter retainer screws 4 Remove the filters and clean or replace as necessary 5 Reassemble in reverse order NOTE Each cartridge has a body filter to provide additional protection from dirt To clean or replace these filters the valve body must be removed from the reservoir and the cartridge removed from the body Clean with solvent and compressed air or replace as required C Models in M 670 M 680 and M 690 Series Like the M 640 series these modes also have port and cartridge filters The port filters are located just below the surface
23. ilters in the system Always wear eye protection and protective clothing when working on and around hydraulic systems Remove jewelry and objects that might conduct electricity while working on power units Hydraulic fluid does pose a fire harard can cause burning or skin irritation if not properly handled Fluid under pressure can pierce the skin and enter the bloodstream causing death or serious injury Devices being operated by the hydraulic system should be immobilized so they cannot move and cause injury while being inspected or repaired Disconnect from electrical source Prior to performing any maintenance make sure the equipment is turned off and that any stored energy for example pressure is released Also extended equipment or cylinders should be lowered and mechanically locked as required Monarch Hydraulics is not responsible for misuse or misapplication of product If you have any questions about application please concact local dealer Fluids should be contained and disposed of prop erly RELIEF VALVES 1 THE PURPOSE OF A RELIEF VALVE IS TO A Keep the maximum system pressure at a safe level LOOSEN JAM NUT 1 TURN SCREW CLOCKWISE TO INCREASE PRESSURE 3 TURN SCREW COUNTER CLOCKWISE TO DECREASE PRESSURE 3 NOTE OUTLET PORT FLOW MUST BE BLOCKED TO MAKE RELIEF VALVE OPERATE WHILE ADJUSTING RELIEF STD 4 TIGHTEN JAM NUT 1 REMOVE FLUSH PLUG 1 TURN SCREW CLOCKW
24. in each outlet C1 C2 C3 To clean or replace proceed as follows 1 Remove the hoses from the valve body 2 Remove the filter retainer screws with a requires proper voltage Any attempt to operate below 1 4 allen key the minimum required voltage could cause system 3 Remove and clean or replace filters as failure Refer to Battery Cable Guide Following page required A Signals which point to low voltages are 4 Reassemble in reverse order The cartridge body filters are removed and repaired in the same manner as described in the M 640 Models above D Most cartridge solenoid valves also have body filters located on the cartridge of the valve Some can be replaced others can only be cleaned NOTE Do not use Teflon tape on hydraulic fittings as it can easily jam valves and plug the filters in the system Always wear eye protection and protective clothing when working on and around hydraulic systems Remove jewelry and objects that might conduct electricity while working on power units Hydraulic fluid does pose a fire harard can cause burning or skin irritation if not properly handled Fluid under pressure can pierce the skin and enter the bloodstream causing death or serious injury Devices being operated by the hydraulic system should be immobilized so they cannot move and cause injury while being inspected or repaired Disconnect from electrical source Prior to performing any maintenanc
25. ing usually hex ball spring and an adjustable screw Its usual function is to control a port at a lower pressure than the main relief in the pump base See Fig 18 SPRING SCREW HOUSING EXTERNAL RELIEF VALVE FIG 18 Troubleshoot and Repair as Follows Dead Head the port in question Tee a gauge into the port start pump and note pressure If it is too high the adjusting screw will need to be turned counterclockwise use 1 4 allen key If it is too low turn the adjusting screw clockwise a turn and note the pressure gauge reading If it does not move turn screw counterclockwise start pump and flush dirt past the ball Then turn the screw to the proper pressure setting Note that the screw threads can be deformed slightly with a small prick punch and hammer to hold the pressure setting Also see Relief Valve section for more general information Cartridge Type Port Relief See section above and Fig 6 on Cartridge Relief Valves for repair Double Pilot Operated Checks DOUBLE PILOT OPERATED CARTRIDGE CHECK FIG 19 Two styles of Double Pilot Operated checks are used One is a cartridge type See Fig 19 The other is made up of two check valves anda pilot piston complete with springs See Fig 20 Both styles can be cleaned by blowing com pressed air through them But the cartridges cannot be disassembled Replace the valves if air does not dislodge the contamination CARTRIOG
26. ing on motor shaft a growling motor can be caused by bad bearings H Check for excessive end play of armature and add thrust washers as required On motors designed with a ball bearing on commutator end make sure the wavy washer is behind the bearing to thrust it toward the pump NOTE A motor that does not turn in freezing weather could be caused by water that has frozen inside the housing I All D C motors turn counterclockwise when viewed from the drive end check it when Cable Length 150 200 Current replacing a motor with a new one J If motor fails to turn the pump check the pump by turning the drive shaft by hand it may be setup and the pump needs replacing Shaft rotates clockwise 3 D C MOTORS Permanent Magnet Permanent magnet motors are similar to wound field motors except the field coils are replaced with perma nent magnets If the brush holder is mounted to the head assembly it must be aligned with timing marks to the motor shell If you cannot find the marks make your own before you loosen the bolts Repair similar to wound field motor above with exception of the field coils Note Permanent magnet motors must be handled with care Timing marks must be properly aligned for maximum performance and efficiency PM motors have powerful magnets which will attract ferous materials Magnets must be kept clean before inserting the armature Keep fingers
27. ion 2 There is no drop tube or down spout on the return line so that the oil is not returning to the bottom of the reservoir 3 Check for a loose suction tube 4 The return oil velocity is excessive to correct add a flow control valve to slow velocity increase size of down spout add a diffuser or use a larger reservoir to increase depth of oil above the end of the return tube 5 Damage to pump seal On systems with the seal cavity connected to suction C Water in the oil Water can enter the reservoir through the fill hole if the unit is left outdoors or washed with high pressure washers Protect the unit whenever possible and change oil regularly to Monarch Hydraulics Inc minimize problems In cold weather the water will freeze and the pump will not work until the ice melts 4 TIPS AND COMMENTS A In most cases the power unit is made to be mounted either vertically or horizontally and improper mounting will not allow the reservoir to be filled to capacity See Pump Priming Section B On units with a remote reservoir try to mount it above the pump whenever possible to flood the inlet C One of the functions of the reservoir is to keep the oil in the proper temperature range If the reservoir cannot dissipate enough heat in crease the size in order to bring the oil tem perature down to the proper level See Hydrau lic Fluid Section D Whenever reinstalling plastic reser
28. limate conditions 2 SELECTING FLUIDS FOR APPLICATIONS OUTSIDE OF ATF S TEMPERATURE RANGE When looking for fluids that can be used in the place of automatic transmission fluid or for applications where the operating temperature is outside of the range of automatic transmission fluid the following specifications should be discussed with your local oil distributor A Fluid must be compatible with Buna N sealing compounds B The pour point must be below the lowest anticipated temperature that will be encountered C It should contain Rust and Oxidation as well as other detergent type inhibitors D The Viscosity SUS should lie between 80 as a minimum and 375 as a maximum in the operating range with ideal viscosity near 200 SUS E The viscosity index should be as high as possible As an example automatic transmission fluid ATF has the following specifications as listed by most oil manufacturers A Viscosity SUS 100 F 185 to 205 210 F 45 to 55 B Pour Point 45 F to 35 F C Viscosity Index 145 to 165 NOTE In an emergency for cold weather applications SAE 10W oil mixed by volume with no more than 30 1 fuel oil or kerosene can be used It must be re moved when the weather warms Always wear eye protection and protective clothing when working on and around hydraulic systems Remove jewelry and objects that might conduct electricity while working on power units Hydraulic fluid does pose a fi
29. lve 8 E Cartridge Check 8 F Lowering Valve 8 G Selector Valve 8 H 2 Way 2 Position Valve 8 J 4 Way 2 Position Valve 8 K 3 Way 2 Position Valve M 683 C3 Cy oe ene aes ra N lt gt Em The following parts sheets are available from Monarch for the following DC Power Unit models Form Number Model Number 2234 M 258 2235 M 259 2155 M 301 2156 M 303 2157 M 304 2263 M 310 2195 M 311 2159 M 313 2242 M 314 2160 M 319 2161 M 326 2223 M 342 2253 M 342 08 2225 M 352 2254 M 352 08 2162 M 500 3 Way 2163 M 500 4 Way 2164 M 500 4 Way 3 Way 2220 M 628 amp 629 2174 M 641 2175 M 642 2176 M 644 2177 M 645 2178 M 647 2179 M 668 2181 M 682 2182 M 683 through M 688 2183 M 693 2212 M 719 2184 M 721 2231 M 3519 2364 M 3519 HF 2232 M 3551 2365 M 3551 HF 2236 Hand Pump 2347 Wiring Guide for Monarch DC Power Units Monarch Hydraulics Inc _ 23 MONARCH HYDRAULICS INC P O Box 1764 Grand Rapids MI 49501 1764 U S A 1363 Michigan St NE Grand Rapids MI 49503 U S A Telephone 616 458 1306 Telefax 616 458 1616 http www monarchhyd com Form No 2369 03 CANADA FLUID
30. making a proper diagnosis HYDRAULIC FLUID 1 THE PURPOSE OF OIL The main purpose of hydraulic fluid is to transfer power from the pump to the actuators but it must also perform many other tasks which are critical to a well designed system First the oil must have good lubricity or be slippery so that the friction will be as low as possible to keep metal to metal wearing at a minimum Second the viscosity or thickness must be in the proper range at Monarch Hydraulics Inc the operating temperature so that unwanted leakage will be at a minimum but will still allow the oil to lubricate the close fitting parts in the system Oil that is too thin will leak past seals valve spools and the gears Oil that is too thick will not flow properly and cause the pump to cavitate or starve Third the oil must be compatible with the seals used in the system Fourth there should also be additives in the oil to slow down the effects of rust oxidation oxygen in the air combining with the oil to form sludge foaming and water settling to the bottom of the reservoir Fifth the oil must be able to pour or flow at the lowest expected temperature so that the oil can reach or get into the pump Sixth the oil should contain EP extreme pressure additives to prevent breaking down the fluid For all the reasons just listed automatic transmission fluid ATF was found in most cases to be the best fluid readily available in most c
31. me into contact with electrical connec tions prior to working on the electrical system Always wear eye protection and protective clothing when working on and around hydraulic systems Remove jewelry and objects that might conduct electricity while working on power units Hydraulic fluid does pose a fire harard can cause burning or skin irritation if not properly handled Fluid under pressure can pierce the skin and enter the bloodstream causing death or serious injury Devices being operated by the hydraulic system should be immobilized so they cannot move and cause injury while being inspected or repaired Disconnect from electrical source Prior to performing any maintenance make sure the equipment is turned off and that any stored energy for example pressure is released Also extended equipment or cylinders should be lowered and mechanically locked as required Monarch Hydraulics is not responsible for misuse or misapplication of product If you have any questions about application please concact local dealer Fluids should be contained and disposed of prop erly NOTES Monarch Hydraulics Inc 19 D C Hydraulic Models Typical Location of Basic Parts 8 Valves 9 Specialty Valves 1 Relief Valve 8 A Lowering Valve 9 A Pressure Compensated Orifice 2 Port Outlets 8 B Port Relief 9 B Adjustable Flow Control 2 A 3 8 Pipe High Pressure 8 C Lowering Valve 4 2 B 1 4 Pipe High Pressure
32. re harard can cause burning or skin irritation if not properly handled Fluid under pressure can pierce the skin and enter the bloodstream causing death or serious injury Devices being operated by the hydraulic system should be immobilized so they cannot move and cause injury while being inspected or repaired Disconnect from electrical source Prior to performing any maintenance make sure the equipment is turned off and that any stored energy for example pressure is released Also extended equipment or cylinders should be lowered and mechanically locked as required Monarch Hydraulics is not responsible for misuse or misapplication of product If you have any questions about application please concact local dealer Fluids should be contained and disposed of prop erly PUMP PRIMING 1 NEW INSTALLATIONS New system installations as well as those that are disassembled for repair require proper priming to avoid possible pump failure A pump is said to be primed when the internal cavity is full of oil and the air has been expelled Prime a pump as follows A Crack or remove the high pressure line at or near the cylinder B Jog the unit until oil flow is clear Air is ab sent C Retighten or replace hose 2 ON SYSTEMS THAT FAIL TO PRIME OR LOSE THEIR PRIME CHECK FOR THE FOLLOWING A Correct unit mounting position Failure to mount the pump in the proper manner could mean that the pump canno
33. re off at its weakest point Likely spots for shorts are switches electrical strain relief electrical junction boxes and control cord s that have been pinched or cut 6 SOLENOID COILS Coils are used in solenoid operated valves and sole noid start switches Failures can be caused by vibra tion water improper voltage or corrosion The best way to test a coil is with an OHM meter The meter should read some value of OHMS and an infinite reading means that the coil has an open circuit The reading between any lead on the coil and the can should be infinite unless there is only one lead wire and the coil is grounded to the can 7 ELECTRICAL POLARITY Motors and valves supplied by Monarch can be used on either positive or negative ground systems with the exception of the model M 310 or any system using the round cylindrical shaped manual valve with a covered switch on the back plate In these units there is a capacitor connected on the switch which must be polarized They are normally wired for negative ground systems and if used on a positive ground system the capacitor must be turned end for end as the sign must face the most positive side of the circuit Failure to align properly will cause the lead wire to blow off the capacitor which in turn could make a ground fault and cause the motor to run with no control NOTE Do not use teflon tape on hydraulic fittings as it can easily jam valves and plug the f
34. rn the adjusting screw counterclockwise all the way out energize the pump to flush the dirt past the seat Inspect the cone or ball for nicks and replace it if necessary reseat the ball or cone using a small drift punch and hammer with a light tap reinstall the spring and adjusting screw and reset the pressure If you replacing a cartridge relief valve it cannot be readily disassembled Push a blunt object into the nose area to push the poppet after you have the screw backed off as far out as possible Blow compressed air thru side port to try and get dirt to exit the way it entered Pick it out if possible If you cannot dislodge the contami nation you will need to replace the cartridge 4 Ifthe above mentioned procedure fails to increase the relief valve setting check for a worn pump or leaking cylinder Note Do not use teflon tape on hydraulic fittings as it can easily jam valves and plug the filters in the system BALL CHECK FIG 7 Always wear eye protection and protective clothing when working on and around hydraulic systems Remove jewelry and objects that might conduct electricity while working on power units B Poppet Type Hydraulic fluid does pose a fire harard can cause A Poppet Type check valve is made up of the burning or skin irritation if not properly handled following See Fig 8 9 10 amp 11 Fluid under pressure can pierce the skin and enter Ball th
35. s Hydraulic fluid does pose a fire harard can cause burning or skin irritation if not properly handled Fluid under pressure can pierce the skin and enter the bloodstream causing death or serious injury Devices being operated by the hydraulic system should be immobilized so they cannot move and cause injury while being inspected or repaired Disconnect from electrical source Prior to performing any maintenance make sure the equipment is turned off and that any stored energy for example pressure is released Also extended equipment or cylinders should be lowered and mechanically locked as required Monarch Hydraulics is not responsible for misuse or misapplication of product If you have any questions about application please concact local dealer Fluids should be contained and disposed of prop erly TABLE OF CONTENTS TOPIC PAGE TOPIC General i Directional Control and Specialty Valves Table of i 2 Way 2 Position Normally Closed Test 1 VAIVES Pressure 1 3 Way 2 Position 4 Way 2 Position D C Test Light 1 VANOS Continuity Light 1 Specialty Valves Volt
36. should be approximately 13 5 volts with no electrical accessories operating and the engine running Check it 2 Operate pump unit under maximum conditions this would be either under full load or when pump is running over relief cylinder dead headed Use the volt meter to probe each connection cable end and cable from the battery all the way back to the motor stud and note the voltage losses Make the necessary repairs Increase the voltage above the minimum required NOTE Check the ground side as well Paint rust 1 LOW VOLTAGE and dirt are insulators remove them Operating direct current D C power units efficiently Monarch Hydraulics Inc 5 00 Gauge 35 0 0 Gauge 1 Gauge Emm 2 Gauge 280 25 7 1 mm 5 1 mm o 0000 Actual area of battery cable copper strand bundle Insulation NOT included 4 Gauge 20 Battery Cable Guide 2 D C MOTORS Wound Field Motors should be serviced periodically to insure proper performance Service as follows A Remove head assembly from motor B Check sleeve bearing in head assembly for wear C Place a few drops of oil on felt liner in head assembly D Check brush set for wear and replace if neces sary E Blow dirt and dust out of motor housing and check for shorts burnt wires or open circuits in the field coil assembly Check armature and commutator for shorts or open circuits G Check ball bear
37. t prime pickup oil because the suction tube is not submerged in the oil at all times B Partially clogged suction filter See Filter Section C Aloose or improperly installed suction hose or pickup tube D A bad front pump seal On systems with the seal cavity connected to suction E A solid fill plug in reservoir with no vent See Reservoir Section F Oil that is too thick reference Hydraulic Fluid Section Occasionally a pump will not prime itself be cause a check valve spring in the high pressure port is too Stiff or the spring retainer is turned down too far If this condition is expected loosen the spring retainer it is found in the high pres sure outlet port energize the pump to prime it and then turn the retainer back to the correct depth See section on check valves Always wear eye protection and protective clothing when working on and around hydraulic systems Remove jewelry and objects that might conduct electricity while working on power units Hydraulic fluid does pose a fire harard can cause burning or skin irritation if not properly handled Fluid under pressure can pierce the skin and enter the bloodstream causing death or serious injury Devices being operated by the hydraulic system should be immobilized so they cannot move and cause injury while being inspected or repaired Disconnect from electrical source Prior to performing any maintenance make sure the equipm
38. voirs make sure that the hose clamp is torqued to 57 inch pounds Always wear eye protection and protective clothing when working on and around hydraulic systems Remove jewelry and objects that might conduct electricity while working on power units Hydraulic fluid does pose a fire harard can cause burning or skin irritation if not properly handled Fluid under pressure can pierce the skin and enter the bloodstream causing death or serious injury Devices being operated by the hydraulic system should be immobilized so they cannot move and cause injury while being inspected or repaired Disconnect from electrical source Prior to performing any maintenance make sure the equipment is turned off and that any stored energy for example pressure is released Also extended equipment or cylinders should be lowered and mechanically locked as required Monarch Hydraulics is not responsible for misuse or misapplication of product If you have any questions about application please concact local dealer Fluids should be contained and disposed of prop erly FILTERS 1 SUCTION FILTERS Most Monarch hydraulic controls have suction filters which must be cleaned periodically or whenever flow is slow or sluggish Some filters can be washed in cleaning solvent and blown dry with compressed air those which cannot be cleaned properly should be replaced External high pressure filters may be added to the system for added protection and ease o
39. witch See one end connected to the post Test Equipment marked and the other end to the 3 Remove the wires from the switch and small center post With the battery touch them together in the proper order to cable connected to the post marked operate system Bat the solenoid switch is energized Note All switch control stations subjected to the by grounding the small post which in weather should be mounted so that the cord exits turn closes the main contacts and the bottom to prevent water from entering the box starts the motor b Testing for a faulty solenoid switch When testing use an OHM meter conti B Contact finger switches Manual Valves mity toht ar test light and check All models that use a contact finger s attached functions as described above See Test to the handle or shaft of a manual valve to start Equipment Section the D C motor do so by grounding the small post of a solenoid start switch When repairing 2 Post Solenoid Switch Fig 2 Ground to systems with contact fingers check for the Can following 1 Improperly aligned or broken contact finger 2 Nub nut assembly that is not insulated from ground 3 Wires that are bare or shorted to ground C Motor Start Solenoid Switches Grounded Can Although there are exceptions most solenoid switches found on Monarch systems are one of a The three post solenoid switch is wired the following three types
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