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500 Troubleshooting Guide 2369-03 PDF
500 Troubleshooting Guide 2369-03 PDF
AND
TROUBLESHOOTING
GUIDE
FOR
MONARCH
‘M’ Series
D.C. HYDRAULIC POWER UNITS
IMPORTANT
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.
! WARNING
• 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.
i
TABLE OF CONTENTS
General Information ......................................... i Directional Control and Specialty Valves .......... 13-15
Table of Contents ............................................. ii 2-Way/2-Position Normally Closed
Test Equipment ................................................ 1 Valves ....................................................... 13-14
Pressure Gauge ........................................ 1 3-Way/2-Position and 4-Way/2-Position
D.C. Test Light .......................................... 1 Valves ....................................................... 14-15
Continuity Light ......................................... 1 Specialty Valves ........................................ 15-17
Volt Meter .................................................. 1 Tips on Repairs ............................................... 18
OHM Meter ............................................... 1 Warning ........................................................... 18
Assorted Hoses, High Pressure Fittings .... 1 Notes ............................................................... 19
High Pressure Shutoff Valve ..................... 1 D.C. Hydraulic Models ..................................... 20-22
Hydraulic Fluid ................................................. 1 Part Sheets Available from Monarch ................ 23
The Purpose of Oil .................................... 1-2
Selecting Fluids for Applications Outside of
ATF’s Temperature Range ........................ 2
Pump Priming .................................................. 2
New Installations ....................................... 2
On Systems That Fail to Prime or Lose
Their Prime, Check for the Following ........ 2-3
Reservoirs ....................................................... 3
Use Recommended Fluid .......................... 3
Correct Filling and Operating Procedure ... 3
Problems Associated with The Reservoir .. 3-4
Tips and Comments .................................. 4
Filters .............................................................. 4
Suction Filters ........................................... 4
Additional Filter Systems ........................... 4-5
Electrical Problems .......................................... 5
Low Voltage ............................................... 5-8
D.C. Motors (Wound Field) ....................... 6
D.C. Motors (Permanent Magnet) ............. 6
Electrical Switches .................................... 7-8
Shorts, “Grounding Faults” and “Open”
Circuits ...................................................... 8
Solenoid Coils ........................................... 8
Electrical Polarity ....................................... 8
Relief Valves .................................................... 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 ................................................... 11
Purpose of a Check Valve ......................... 11
Three Types of Check Valves are Used .... 11-12
Troubleshooting and Repairing Check
Valve Failures ............................................ 12
3. CONTINUITY LIGHT
! WARNING 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
• Always wear eye protection and protective clothing
battery. They are easily obtained from discount stores
when working on and around hydraulic systems. or electrical jobbers at modest cost.
• Remove jewelry and objects that might conduct
4. VOLT METER
electricity while working on power units.
A D.C. volt meter, as used in the automotive repair
• Hydraulic fluid does pose a fire harard, can cause
business, is a good investment for troubleshooting
burning or skin irritation if not properly handled. problems that are related to low voltage. They are used
• Fluid under pressure can pierce the skin and enter in two ways: first, one probe is grounded while the
the bloodstream causing death or serious injury. other is used to probe the “HOT” leads, the meter
• Devices being operated by the hydraulic system shows the voltage available at the point where the
second probe is connected; second, they can be used
should be immobilized so they cannot move and
to measure a voltage drop in a wire, one probe is
cause injury while being inspected or repaired.
connected to one end and the remaining to the other
Disconnect from electrical source.
end, the reading is the voltage drop.
• Prior to performing any maintenance make sure the
equipment is turned off and that any stored energy, 5. OHM METER
for example pressure, is released. Also, extended An ohm meter is used to measure resistance and is a
equipment or cylinders should be lowered and very useful tool when working on wire circuits and
mechanically locked as required. solenoid coils. On some coils the wire resistance is up
• Monarch Hydraulics is not responsible for misuse or to a level where a D.C. test light might show an open
circuit and it really is not so. An infinite meter reading
misapplication of product. If you have any questions
on any test shows that the circuit is open. A coil test,
about application, please concact local dealer.
however, will always show some value of resistance but
• Fluids should be contained and disposed of prop- it must not be infinite. All tests conducted with an ohm
erly. meter must be done with the battery disconnected from
the system.
6. ASSORTED HOSES, HIGH PRESSURE FITTINGS
NOTE: Do not use Teflon tape on hydraulic fittings
as it can easily jam valves and plug the filters in the These can be used to connect and/or isolate certain
system. 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.
TEST EQUIPMENT 7. HIGH PRESSURE SHUTOFF VALVE
The following is a list of the test equipment required to The shutoff valve can be used to choke off oil flow so
troubleshoot D.C. powered hydraulic systems. that a “false” load can be put on the pump and other
components. With the valve installed it can be slowly
1. PRESSURE GAUGE shut off while the equipment listed above records the
A small 0-5000 Pressure gauge, preferable glycerin filled, data for making a proper diagnosis.
is a very valuable and relatively inexpensive tool for
checking pressure in the various sections of the circuit.
HYDRAULIC FLUID
2. D.C. TEST LIGHT
A test light is simply a light bulb which has one end 1. THE PURPOSE OF OIL
connected by a wire to an alligator clip and the other The main purpose of hydraulic fluid is to transfer power
end connected to a metal probe. It is used to check the from the pump to the actuators but it must also perform
electrical circuit when the battery is connected to the many other tasks which are critical to a well designed
system. The alligator clip is grounded and the light system. First, the oil must have good lubricity or be
glows when the probe comes in contact with a “HOT” “slippery” so that the friction will be as low as possible to
electrical component. They are easily obtained from keep metal to metal wearing at a minimum. Second, the
automotive jobbers or discount stores. viscosity or “thickness” must be in the proper range at
2
B. Partially clogged suction filter. (See Filter RESERVOIRS
Section.)
C. A loose or improperly installed suction hose or 1. USE RECOMMENDED FLUID
pickup tube. Fill reservoir with the approved fluid and refer to the
Hydraulic Fluid Section.
D. A bad front pump seal. (On systems with the
seal cavity connected to suction.) 2. CORRECT FILLING AND OPERATING
PROCEDURE
E. A solid fill plug in reservoir with no vent. (See
Reservoir Section.) A. Operate unit several times starting with short
cylinder strokes and increasing length with each
F. Oil that is too thick - reference Hydraulic Fluid successive stroke.
Section.
B. Recheck oil level often and add as necessary to
G. Occasionally, a pump will not prime itself be- keep pump from picking up air.
cause a check valve spring in the high pressure
port is too “Stiff” or the spring retainer is turned C. After system is completely “bled” check oil level
down too far. If this condition is expected, loosen in reservoir as described in owner’s manual and
the spring retainer (it is found in the high pres- install the filler/breather plug provided.
sure outlet port), energize the pump to prime it,
NOTE: Do not use a solid plug or a fill cap without
and then turn the retainer back to the correct
a filler/breather element or damage will be caused
depth. (See section on check valves.)
to pump and/or reservoir.
C. One of the functions of the reservoir is to keep These specific models have filters in addition to
the oil in the proper temperature range. If the the pump suction filter for protecting the valve.
reservoir cannot dissipate enough heat in- One is located inside the two piece hex fitting
crease the size in order to bring the oil tem- just ahead of the DR (2-way, 2-position) car-
perature down to the proper level. (See Hydrau- tridge lowering valve inside the reservoir. It can
lic Fluid Section). be taken apart for cleaning or replacing the filter
element.
D. Whenever reinstalling plastic reservoirs make
sure that the hose clamp is torqued to 57 inch B. Models in M-640 Series
pounds. These models also are equipped with additional
filters for protecting the solenoid valves. First;
each port, C1, and C2, on the flat surface have
! WARNING a cone shaped filter in the valve body. They can
be reached as follows:
• Always wear eye protection and protective clothing 1. If the ports, C1 and C2, on the flat surface
when working on and around hydraulic systems. are not being used, remove the flush 1/4"
pipe plugs.
• Remove jewelry and objects that might conduct 2. If the ports, C1 and C2 on the flat surface
electricity while working on power units. are being used; remove the hoses.
• Hydraulic fluid does pose a fire harard, can cause 3. Reach down into these ports with a 1/4"
burning or skin irritation if not properly handled. allen key and remove the filter retainer
• Fluid under pressure can pierce the skin and enter screws.
4. Remove the filters and clean or replace as
the bloodstream causing death or serious injury.
necessary.
• Devices being operated by the hydraulic system 5. Reassemble in reverse order.
should be immobilized so they cannot move and NOTE: Each cartridge has a “body” filter to
cause injury while being inspected or repaired. provide additional protection from dirt. To clean
Disconnect from electrical source. or replace these filters the valve body must be
• Prior to performing any maintenance make sure the removed from the reservoir and the cartridge
equipment is turned off and that any stored energy, removed from the body. Clean with solvent and
for example pressure, is released. Also, extended compressed air or replace as required.
equipment or cylinders should be lowered and C. Models in M-670, M-680, and M-690 Series
mechanically locked as required.
Like the M-640 series these modes also have
• Monarch Hydraulics is not responsible for misuse or
port and cartridge filters. The port filters are
misapplication of product. If you have any questions located just below the surface in each outlet
about application, please concact local dealer. (C1, C2, C3). To clean or replace proceed as
• Fluids should be contained and disposed of prop- follows:
erly.
1. Remove the hoses from the valve body.
4
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
failure. Refer to Battery Cable Guide. (Following page)
3. Remove and clean or replace filters as
required. A. Signals which point to low voltages are:
1. The minimum voltage between the motor
4. Reassemble in reverse order.
stud and ground is 9.0 volts at maximum
The cartridge “body” filters are removed and load conditions.
repaired in the same manner as described in 2. The minimum voltage between the valve
the M-640 Models above. solenoid power wire (“hot wire”) and ground
is 9-1/2 volts at maximum load conditions.
D. Most cartridge solenoid valves also have “body”
filters located on the cartridge of the valve. C. Causes for low voltage are:
Some can be replaced, others can only be 1. Battery capacity too small.
cleaned. 2. Cable ends not electrically secure to
battery cable.
NOTE: Do not use Teflon tape on hydraulic 3. Battery cable size too small for load and
fittings as it can easily jam valves and plug length of run. See Battery Cable Guide
the filters in the system. below. Larger copper battery cable, #1, #0,
or #00, may be required for cable lengths
over 25 feet to keep performance from
!
deteriorating.
WARNING 4. Ground cable size not equivalent or larger
than the battery “hotside” cable.
• Always wear eye protection and protective clothing 5. Bad joints where cable ends are bolted to
when working on and around hydraulic systems. battery, motor solenoid, start switch,
• Remove jewelry and objects that might conduct ground and etc.
electricity while working on power units. 6. Burnt contacts on motor solenoid or start
switch.
• 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 PLEASE REMOVE ALL RINGS,
the bloodstream causing death or serious injury.
• Devices being operated by the hydraulic system
! WATCHES AND JEWELRY PRIOR TO
DOING ANY ELECTRICAL
should be immobilized so they cannot move and
cause injury while being inspected or repaired.
Disconnect from electrical source. D. Check for low voltage as follows: (A volt meter
• Prior to performing any maintenance make sure the will be required).
equipment is turned off and that any stored energy, 1. On vehicles equipped with an alternator the
for example pressure, is released. Also, extended voltage should be approximately 13.5 volts
equipment or cylinders should be lowered and with no electrical accessories operating
mechanically locked as required. and the engine running - Check it.
2. Operate pump unit under maximum
• Monarch Hydraulics is not responsible for misuse or
conditions; this would be either under full
misapplication of product. If you have any questions load or when pump is running over relief
about application, please concact local dealer. (cylinder dead headed). Use the volt meter
• Fluids should be contained and disposed of prop- to probe each connection, cable end, and
erly. cable from the battery all the way back to
the motor stud and note the voltage losses.
Make the necessary repairs. Increase the
ELECTRICAL PROBLEMS 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
Cable Length
40'
30'
20'
Actual area of battery cable copper strand bundle.
(Insulation NOT included.) #4 #2 #1 #0 #00
10'
Current
250 300
(Amps)
Motors should be serviced periodically to insure proper J. If motor fails to turn the pump, check the pump
performance. by turning the drive shaft by hand - it may be
Service as follows: “setup” and the pump needs replacing. Shaft
rotates clockwise.
A. Remove head assembly from motor.
B. Check sleeve bearing in head assembly for
3. D.C. MOTORS (Permanent Magnet)
wear.
Permanent magnet motors are similar to wound field
C. Place a few drops of oil on felt liner in head
motors except the field coils are replaced with perma-
assembly.
nent magnets. If the brush holder is mounted to the
D. Check brush set for wear and replace if neces- head assembly, it must be aligned with timing marks to
sary. the motor shell. If you cannot find the marks, make your
own before you loosen the bolts. Repair similar to
E. Blow dirt and dust out of motor housing and wound field motor above with exception of the field
check for shorts, burnt wires, or open circuits in coils.
the field coil assembly.
Note: Permanent magnet motors must be handled
F. Check armature and commutator for shorts or with care. Timing marks must be properly aligned
open circuits. for maximum performance and efficiency. PM
G. Check ball bearing on motor shaft, a growling motors have powerful magnets which will attract
motor can be caused by bad bearings. ferous materials. Magnets must be kept clean
before inserting the armature . Keep fingers away
H. Check for excessive “end play” of armature and from the area between the armature and the motor
add thrust washers as required. (On motors case when re-installing the armature in order to
designed with a ball bearing on commutator avoid injury.
end make sure the wavy washer is behind the
bearing to thrust it toward the pump.)
THE MAGNETS WILL PULL THE
NOTE: A motor that does not turn in freezing
weather could be caused by water that has frozen
! ARMATURE INTO THE MOTOR
UPON REINSERTION.
inside the housing.
I. All D.C. motors turn counterclockwise when A wiring diagram guide for D.C. power units is also
viewed from the drive end - check it when available. Request form #2347-99.
6
4. ELECTRICAL SWITCHES 1. 3 Post Solenoid Switch ( Fig 1.) (Insulated
Can)
A. Push Button, 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. Use a circuit “test light” to test switch. (See one end connected to the post
Test Equipment). marked ‘Bat” 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:
B. “Contact finger” switches (Manual Valves). When testing use an OHM meter, conti-
nuity light, or test light, and check all
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. 3 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.
FIG. 2
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: and constructed as follows:
(1.) One large post must be attached to
the cable leading from the battery.
(2.) The small post connects to the
Battery
Terminal + control circuit. (Push button, rocker
FIG. 1 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.
a. The four post solenoid switch is wired NOTE: Do not use teflon tape on hydraulic fittings
and constructed as follows: as it can easily jam valves and plug the filters in the
(1.) One large switch post is connected system.
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
! WARNING
the coil, one post to each end. • Always wear eye protection and protective clothing
(4.) With access to both ends of the coil, when working on and around hydraulic systems.
the specific wiring arrangements
can be varied, but to energize the
• Remove jewelry and objects that might conduct
coil one lead has to be positive and electricity while working on power units.
the other end negative. • Hydraulic fluid does pose a fire harard, can cause
b. Testing for a faulty solenoid switch: burning or skin irritation if not properly handled.
When testing use an OHM meter, conti- • Fluid under pressure can pierce the skin and enter
nuity light, or test light, and check all
the bloodstream causing death or serious injury.
functions as described above. (See
Test Equipment Section). • Devices being operated by the hydraulic system
should be immobilized so they cannot move and
5. SHORTS, “GROUNDING FAULTS” AND “OPEN” cause injury while being inspected or repaired.
CIRCUITS Disconnect from electrical source.
In control wiring, shorts can only occur when “hot” lines • Prior to performing any maintenance make sure the
(lines connected directly to the battery) come in contact equipment is turned off and that any stored energy,
with ground. A short will either cause a fuse to blow, if for example pressure, is released. Also, extended
there is one, or burn the wire off at its weakest point. equipment or cylinders should be lowered and
Likely spots for shorts are switches, electrical strain mechanically locked as required.
relief, electrical junction boxes, and control cord(s) that
have been pinched or cut.
• Monarch Hydraulics is not responsible for misuse or
misapplication of product. If you have any questions
6. SOLENOID COILS about application, please concact local dealer.
Coils are used in solenoid operated valves and sole- • Fluids should be contained and disposed of prop-
noid start switches. Failures can be caused by vibra- erly.
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
RELIEF VALVES
reading means that the coil has an open circuit. The
reading between any lead on the coil and the “can” 1. THE PURPOSE OF A RELIEF VALVE IS TO:
should be infinite unless there is only one lead wire and A. Keep the maximum system pressure at a safe
the coil is grounded to the can. level.
8
FLOW
5
4
3
2
1
FLOW
4 SPRING
3
2
1
FIG. 5
B. Keep the amp draw and battery drain at a 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.
NOTE: When adjusting the relief valve be sure to (3) If you are replacing a cartridge
use a pressure gauge and consult with the manu- relief valve it cannot be readily
facturer for the proper pressure setting. Failure to disassembled. Push a blunt object
accurately set the relief valve can cause failure into the nose area to push the
resulting in damage to the equipment or cause poppet after you have the screw
bodily harm. backed off as far out as possible.
Blow compressed air thru side port
B. Relief Valve Pressure Too Low to try and get dirt to “exit” the way it
1. Symptoms: “entered”. Pick it out if possible. If
a. Motor RPM is faster than normal. you cannot dislodge the contami-
b. Cylinder will not extend. nation you will need to replace the
c. Excessive turbulence in the reservoir. cartridge.
10
(4) If the above mentioned procedure
fails to increase the relief valve
setting, check for a worn pump or
leaking cylinder.
FLOW
Note: Do not use teflon tape on hydraulic fittings
as it can easily jam valves and plug the filters in the
system.
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 &11)
• Fluid under pressure can pierce the skin and enter • Ball
the bloodstream causing death or serious injury. • Ball Follower
• 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 FLOW
FIG. 8
CHECK VALVES
FIG. 12
12
! WARNING
• 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.
FIG. 15
14
the cartridge from the valve body and blow If flow is blocked it could be because a particle
compressed air through all parts to dislodge of dirt has covered the orifice hole in the piston.
dirt. Clean all parts in solvent, blow dry, It could also be caused by a piston that has
and lubricate. “over travelled” the return ports in the side of
the housing and has become “jammed” in
B. If the valve does not return to the neutral or
contamination at the bottom of the cavity. The
unshifted position, check for dirt in the valve
inner housing and piston can be removed as an
cartridge and repair in the same manner as
assembly. Inspect orifice hole for dirt and blow
above.
compressed air through side holes to dislodge
3. SPECIALTY VALVES: contamination. Push on inner piston with a
blunt object and observe the piston moving past
A. Cartridge Style Check Valves. side holes in the housing. If it is smooth, it is
These valves screw into a cartridge cavity and working properly. If it is sticky, remove push clip
allow for free flow from the end to the side and and disassemble. Clean with solvent and
block reverse flow. (See Fig. 12) compressed air, oil the parts, and reassemble.
Do not use emery paper or steel wool to polish
Troubleshoot and Repair as Follows: parts or touch orifice with a pick or drill bit
(compressed air only). Replace as an assem-
If the valve does not hold, remove the bly if it does not work properly.
cartridgefrom the housing. Blow compressed
air through the cartridge from the side to the C. Adjustable Flow Control.
bottom while holding the ball or poppet off the
seat (use a blunt object inserted through the This valve has a needle to adjust oil flow in the
bottom of the cartridge to hold the poppet off direction of the arrow. It has an internal check
the seat. valve so reverse flow (opposite the arrow) is
unaffected by the needle.
NOTE: The valve itself cannot be disassembled in
Troubleshoot and Repair as Follows: (See Fig.
the field; replace it if cleaning does not the problem.
17).
B. Pressure Compensated Orifice. CONTROLLED FLOW
DIREC TION
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)
CONTROLLED FLOW
PRESSURE COMPENSATED ORIFICE Open needle by loosening the jam nut on the
stem and turn the stem out. Inspect for dirt in
FIG. 16
ports and remove if possible. Blow com-
BALL
SPRING
SCREW
HOUSING DOUBLE PILOT OPERATED CARTRIDGE CHECK
FIG. 19
FLOW
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 and a
pilot piston complete with springs (See Fig. 20).
Both styles can be cleaned by blowing com-
pressed air through them. But the cartridges
EXTERNAL RELIEF VALVE cannot be disassembled. Replace the valves if
air does not dislodge the contamination.
FIG. 18
16
SPRINGS
4 3
1 2
PISTON
4 3
CROSS CHECK WITH MANUAL OVERRIDE
SCREW ACTUATOR STYLE SHOWN ALSO
AVAILABLE WITH PLUNGER
FIG. 21
1 2
FIG. 20
! WARNING
• 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.
18
NOTES :
8C
M-303 2B
5 1
OUTLET PORT
3/8 NPT REF
OUTLET PORT
3/8 NPT REF
2A
5
M-304
20
4
M-258
PORT
1
8C
6 TO
BATTERY
8A
4
2A
6
OUTLET PORT
SHOWN WITH
OPTIONAL MOUNTING
1 BRACKET
M-3519
3
8J 4
8H
M-3551
6
2 C2 C1
9A
5
1 C2 PORT RV
PRESS. COMP.
ORIFICE
8B
+ M
M-683
C3 C1 C2
A
B
8H
8J
8B
8H
8K
M-3593
5 C3 C2 C1
22
The following parts sheets are available from Monarch for the following DC Power Unit models:
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 & 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