monarch hydraulic pump troubleshooting(guide &solutions)

I bet you’re having trouble with monarch hydraulic pump troubleshooting. I know that’s the case. You see, it’s easy to become stuck on something simple if you don’t know exactly what to do. That’s why I’ve created this article and put together everything I learned about monarch hydraulic pump troubleshooting, and applied it in a very detailed set of instructions.

monarch hydraulic pump Unable to start

1.Do not worry if your hydraulic pump, commonly known as a hydraulic lifter, fails to engage when the throttle is engaged. There are several possible solutions to solve this problem..

2.Correct unit mounting position. Failure to mount the pump in the proper manner could mean that the pump cannot prime because the suction tube is not submerged in the oil at all times.

3.Partially clogged suction filter. (See How to replace the Filter.)

4.A loose or improperly installed suction hose or pickup tube.

5.Abad front pump seal. (On systems with the seal cavity connected to suction.)

6.A solid fill plug in reservoir with no vent. (See Reservoir Section.)

7.Oil that is too thick – reference Hydraulic Fluid Section.

8.Occasionally, a pump will not prime itself because 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 pressure outlet port), energize the pump to prime it, and then turn the retainer back to the correct depth. (See section on check valves.)

Monarch Hydraulic Pump Low Voltage

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.
3. .Causes for low voltage are:

A. Battery capacity too small.
B. Cable ends not electrically secure to battery cable.
C. 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.
D. Ground cable size not equivalent or larger than the battery “hotside” cable.
E. Bad joints where cable ends are bolted to battery, motor solenoid, start switch, ground and etc.
F. Burnt contacts on motor solenoid or start switch.

Check for low voltage as follows

1. Onvehicles equipped with an alternator the voltage 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.

Monarch Hydraulic Pump D.C. MOTORS check

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 necessary.

E. Blow dirt and dust out of motor housing and check for shorts, burnt wires, or open circuits in the field coil assembly.

F. Check armature and commutator for shorts or open circuits.

G. Check ball bearing 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.)

I. All D.C. motors turn counterclockwise when viewed from the drive end – check it when 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.

monarch hydraulic pump circuits, shorts

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 wire 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.

diagnosing and repairing relief monarch hydraulic pump 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 cylinder movement is zero).

A. Relief Valve Pressure Too High

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.

Repair Procedure:
Turn relief valve adjusting screw counterclockwise using a gauge, tee’d into the high pressure line, to record the proper pressure setting.

!!!NOTE: When adjusting the relief valve be sure to use a pressure gauge and consult with the manufacturer 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

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.

Repair Procedure
a. There are 2 possible causes for lack of pressure.
(1)The adjusting screw has backed up.
(2)Foreign matter or “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; if it 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).

(2)If the pressure does not increase when the adjusting screw is tightened; turn 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.

(3)If you are 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 contamination you will need to replace the cartridge.

(4)If the above mentioned procedure fails to increase the relief valve setting, check for a worn pump or leaking cylinder.

Step-by-Step Troubleshooting Guide for Monarch Hydraulic Pumps

Troubleshooting Monarch Hydraulic Pumps involves a systematic approach to identify and rectify common issues affecting pump performance and reliability. By following this step-by-step guide, operators and maintenance personnel can diagnose and address problems efficiently.

Initial Checks and Diagnostics

1. Visual Inspection: Begin with a thorough visual inspection of the pump and associated hydraulic system for any obvious signs of wear, damage, or leaks. Pay special attention to hoses, fittings, and seals.
2. Check Hydraulic Fluid Levels and Quality: Ensure the hydraulic fluid is at the correct level and inspect it for signs of contamination, such as water or particulate matter. Replace the fluid and filter if necessary.
3. Inspect the Pump Drive System: Verify that the pump is properly aligned and the drive system (belts or couplings) is in good condition, correctly tensioned, and not causing any undue strain on the pump.

Troubleshooting Common Issues

• Decreased Pressure Output:
  • Check for leaks in the system that might be causing a drop in pressure.
  • Inspect the relief valve to ensure it is not stuck open.
  • Evaluate the condition of the pump’s internal components for wear or damage that may be affecting performance.
• Abnormal Noise or Vibration:
  • Identify the source of the noise or vibration. Loose components, bearing failure, or cavitation could be the culprits.
  • Ensure that the pump is not cavitating due to low fluid levels or blockages in the intake line.
• Overheating:
  • Verify that the cooling system is functioning correctly and that the hydraulic fluid has not degraded.
  • Check for excessive loads on the pump that may be causing it to work harder than designed.
• Fluid Leaks:
  • Tighten or replace leaking fittings or seals.
  • Inspect the pump housing for cracks or damage that may necessitate repair or replacement.
• Erratic Pump Operation:
  • Purge air from the system to resolve sponginess or erratic operation.
  • Check the condition and operation of control valves that may be affecting system performance.

Advanced Troubleshooting Techniques

• If basic troubleshooting does not resolve the issue, consider consulting the pump’s documentation for specific diagnostic procedures or contact a professional for advanced diagnostics, which may involve checking internal pump tolerances, testing the hydraulic circuit’s pressure and flow rates, or inspecting the pump under operation.
• When to Consider Professional Repair or Replacement:
  • If the pump’s internal components are significantly worn or damaged, professional repair or complete replacement may be necessary.
  • When the issue persists despite thorough troubleshooting, seeking professional assistance ensures that more complex problems are correctly diagnosed and resolved.

Following this guide will help in effectively diagnosing and fixing common problems encountered with Monarch Hydraulic Pumps. Regular maintenance and timely troubleshooting are key to extending the life of hydraulic pumps and ensuring their reliable operation in various applications.

troubleshooting and repairing check valve failures

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.
c. Remove ball or follower and ball.
d. Start pump to “flush” dirt from the seat
area. (Caution: divert oil into a container. Do not look into the port).
e. Inspect the ball for damage and replace if necessary.
f. Reinstall bal! or ball and follower.
g. “Seat” the ball using a small drift punch and hammer with a light tap.
h. Reinstall the spring.
i. Replace the spring retainer to the correct depth.

3.Repair Procedure (Cartridge)
Remove cartridge and clean or replace.

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 relief.

2..Repair Procedure (Loose Parts Design)
a. Remove the check valve components 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)
Replace cartridge (See Specialty Valve Section A)

Monarch Hydraulic Pump Parts Diagram

Typical Location of Basic Parts:

1.Relief Valve

2.Port Outlets

2-A 3/8″ Pipe = High Pressure

2_-B 14″ Pipe – High Pressure

3.Suction Filter

4.Mator Start Solenoid Battery Post

5.Fil – Vent Plug

6.Check Valves

7.Port Flter Locations

8.Valves

8-A Lowerin Vave

8-B Port Relief

8-C Lowering Valve

8-D Lowering Valve

8-E Cattridge Check

8-F Lowering Valve

8-G Selector Valve

8-H 2-Way2-Posilin Valvo

8-J 4-Way/2-Position Valve 8-K 3-Waya2-Positin Valve

9.Spedalty Valves

9-A Pessr Compensate Orfitie

9-B Adjustable Flow Control

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 & 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 hydraulic pump troubleshooting fAQ?

monarch hydraulic pump manual troubleshooting video

So, to wrap it up: if you have a Monarch Lift, there’s a chance that your hydraulics will stop working. You’ll need to replace the seals that keep water from leaking past the actuator piston. It’s a lot of work, but it’s also a very straightforward process. Just be sure you have all of the right parts and some help from an experienced mechanic if you get stuck!