Twin-3 system fault finding at machine without diagnostic tool AC1305.

004

1. Empty grease reservoir (error code E15)?

NO YES Fill the grease reservoir YES Check the system functionality after empty!
Disconnect a secondary line, start a multiple test cycle
(TEST push button ≥ 6 sec.) and check over a number of cycles
whether system supplies grease again at this line.
When no grease supply, continue with point 2.
(test cycles can be ended by simply switching-OFF ignition).

2. Install test manometers

YES NO Install 2 manometers in the system (minimal 250bar)
Preferable at both pump outlets, using T-couplings.

3. Motor run? Start a single test cycle by holding the TEST button at the pump in between 2 and 6 seconds
(test cycle can be ended by switching-OFF ignition).
YES NO Power at pump connector?
Check voltage at pump connector pin 1(+) and 2 (-).
YES NO Ignition switched-OFF Switch-ON and resume at point 3.
Broken fuse Exchange fuse (see electrical diagram).
Contact 1 or 2 out of position Restore lock clips.

Damaged wiring restore wiring and resume point 3.

Power at controller-board? Check power connector on controller board in motor compartment.

YES NO Restore power connection

and resume at point 3.

Pump motor circuit OK? Shorted or broken motor circuit.

YES NO Motor disconnected from controller board Connect and resume point 3.
(Error code E22)
Motor circuit broken Exchange pump, or
(Error code E22)
Motor circuit shorted Exchange pump and resume point 3.
(Error code E23)
Controller board corroded? Check controller board (both sides).
NO YES Exchange pump, check parameter settings and
resume at point 3.

Controller board broken Exchange controller board, check

parameter settings and resume at point 3.
4. Sufficient pressure built? Pump should build pressure in one of the main line channels, until the pressure switch ends the
(error code E11 or E12) pumping phase. When no PS-signal, the pump phase will be ended after exceeding the max
allowed pump run time (approx. 6 to 15min. depending on parameter setting).
YES NO External grease leakage? Check main-line and distribution blocks.
NO YES Repair system and resume with point 4.

Grease output pump? Disconnect both main-line hoses from pump and check grease output while
performing a single test cycle. Pump should produce steady grease flow
without air pockets!
YES NO Air pockets in pump? Start single test cycles until solid grease stream without
air pockets, whilst filling reservoir to max.
When still no grease after ±10minutes while pump runs
smooth and easy
YES Exchange pump , check parameter settings and resume at
point 4.

5/2 way valve stuck? Stuck in between outlet-A and B.

Pump runs heavily on maximum pressure internally!
YES Exchange pump , check parameter settings and resume at
point 4.

Internal pump leakage? Internal leakage prevents pump from building sufficient pressure. Connect
test manometers directly to the pump outlets (system disconnected) and
start a single test cycle (should show 220-250bar in a matter of seconds).
NO YES Does not reach 220-250bar Exchange pump , check parameter settings and
resume at point 4.
Check grease filter on cracks!
Internal leakage can be caused by
contaminated piston valves!

Pump pressure hold? Pump should be able to hold a minimum pressure of 180bar, 1 minute after
stopping the pump. Start a single test cycle for outlet-A and disconnect power
after reaching the maximum pressure.
NOTE
Prescribed test does not work for outlet-B, so when started in B > switch-OFF
ignition and start new test cycle, which automatically will be executed in A again)
YES NO Exchange pump, check parameter settings and resume at point 4.

Check grease filter on cracks!

Internal system leakage? Internal leakage in one of the distribution blocks.
YES How to check?
1. Reconnect 1 system hose to the pump outlet B and let the other hose
disconnected.
2. Now start a single test cycle (automatically performed in B for last was
in A). When grease keeps running from the loose hose this indicates a
leakage in one of the distribution blocks in the system.
Note
A small amount of grease is normal, because each injector unit returns
a small amount during a pumping phase.
Locate the leaking distribution block!
YES How to locate?
1. In order to locate the leaking block, the above described "check"
procedure needs to be repeated after disconnecting the B-hose, just
past the first distribution block (like indicated in drawing below).
2. When grease still flows from system hose ahead, repeat procedure with
the next block in line.
3. Keep repeating procedure until leaking block is located.

Bottom O-ring injector-unit missing or damaged? Check all injector units in this block on missing
bottom O-rings. Often happens when customers
switched position of individual injector-units.

NO YES Place new O-rings and resume at point 4.

Single bearing extremely over greased? Missing or damaged O-ring inside injector-unit, allowing
grease pressure to pass towards connected bearing.
Often happens when customer disassembled injector-units.
NO YES Exchange injector-unit, that serves this bearing and resume at point 4.

Leakage in distribution block! Exchange distribution block and resume at point 4.

5. Pressure relieve? Does the pump relieve the build up pressure to the reservoir at the end of the "pressure hold phase",
(Error code E13 or E14) by switching over the integrated 5/2-way valve?

YES NO Valve coil circuit OK? Shorted or broken valve circuit / check wiring in behind pump bottom cover.
YES NO Valve cable disconnected Restore at position of solenoid or controller board
(Error code E24) and resume at point 4.

Broken circuit in valve coil Exchange pump,

(Error code E24)
Shorted circuit in valve coil Exchange pump
(Error code E25)
Controller board corroded Check controller board condition (both sides)
NO YES Exchange pump

Controller board broken Exchange circuit board

Valve stuck Exchange pump, check parameter settings and resume at point 4.

Check grease filter on cracks!

6. Pressure switch circuit broken? Pressure switch cable damaged externally or internally and therefore the pump
(Error code E21) cannot be stopped after reaching the required pressure. Eventually the controller will
stop the pumping phase after exceeding the max. allowed pump run time (default 10min.).

How to check?
1. Locate the pressure switch in one of the distribution blocks.
2. Remove the 2-pole connector.
3. Start a single test cycle with the TEST push button at the pump (hold 2-6 sec.)
4. The moment you bridge both poles in this 2-pole connector at the cable, the pump
should stop directly.

NO YES Renew or repair cable harness and resume at point 4?

7. Does the press. switch contact close? Contact should close at 100, 125, 150 or 175bar depending on the setting, based on
(Error code E11 or E12) the position in the system (the pressure setting is printed in the side of the
switch).

NOTE
At low temperatures the pressure reading at the pump can be significantly higher.

How to check?
1. Remove the 2-pole connector.
2. Start a single test cycle with the TEST push button at the pump (hold 2-6 sec.)
3. Check with Multi-Meter whether contacts at switch close at mentioned pressure.
YES NO Air pockets in pressure switch valve? Air pockets in the valve direct below the switch could cause
malfunction of the switch.
NO YES How to solve?
1. Remove the switch from the valve and start a single TEST cycle.
2. Bleed the valve until solid grease flow (end TEST cycle by ignition switch-OFF)
3. Repeat procedure to bleed also the other main-line channel in this valve.
4. Install pressure switch again and start a single TEST cycle to check whether
pump is stopped by the pressure switch after exceeding its pressure setting.

Switch broken Renew the pressure switch and start a single TEST cycle to check whether pump is
stopped by the pressure switch after exceeding its pressure setting.

8. Does the press. switch contact open? Switch contact should open as soon the pressure sinks below the pressure setting.
(Error code E13 or E14)
Note
Since 2008 the pressure switches are equipped with a 22kΩ resistor, a value that
shows when contact opened.
YES NO Switch broken Renew the pressure switch and start a single TEST cycle to check whether pump is
stopped by the pressure switch after reaching the set pressure in the block.

9. Problem solved?

10. TEST cycles! We advise to perform minimal 2 "Single TEST cycles" with the button at the pump, to make sure that
the system operates correctly in both main-line channels. When problem not adequate solved, please
repeat the procedure starting at 1.

11. Disassemble the TEST manometers!