The Hydraulic is a generator-set controller. It is used on generator sets from Cummins/Onan, including the RBAA.
| Symptom | Cause | Remedy |
|---|---|---|
| D falls out outside the range | Reinstall the PTO with a gear ratio that will keep pump speed within the specified range at all engine speeds. | |
| FREQUENCY TOO HIGH OR TOO LOW OR ERRATIC | Misadjusted frequency, Pump speed too high or too low, Worn motor or pump | Adjust frequency as necessary (Page 14), Verify that the combination of PTO speed ratio and engine speed range results in pump speeds that fall within the specified range of 850 to 3000 rpm. If pump speed falls outside the range, reinstall the PTO with a gear ratio that will keep pump speed within the specified range at all engine speeds, Replace the worn motor (Page 15) or worn pump (Page 11) |
| FREQUENCY TOO HIGH OR TOO LOW OR UNSTABLE | Wrong PTO speed ratio, The Hydraulic Pump or Controller needs service | Change the PTO gear ratio if pump speed at engine idle or maximum engine speed falls outside the Min-Max pump speed range (A.); Service the hydraulic pump or controller by an authorized Sunsource Inc. representative (B.). |
| Faulty generator or AVR | See an authorized Onan dealer. | |
| HYDRAULIC OIL TEMPERATURE DOES NOT DISPLAY | Faulty Lead Harness, Misconnected or faulty oil temperature sensor, Faulty Display Module | Check for bent, corroded or missing connector pins and damaged leads in harnesses 338-4088 (A.); Check for proper connections of the oil temperature sensor (B.); Replace the display module as necessary (C.). |
| NO AC OUTPUT OR AIR DISCHARGE—ENGINE RUNNING | 1. ON/OFF Switch OFF | A. Turn the switch ON. |
| NO AC OUTPUT—DISPLAY MODULE INDICATES VOLTAGE | 1. Line circuit breaker (vehicle AC distribution panel) OFF, TRIPPED or faulty | A. If the circuit breaker is OFF, find out why, make sure it is safe to reconnect power, and then switch it ON. B. If the circuit breaker TRIPPED, shut down the genset and repair the shorted or grounded equipment that caused tripping. C. Replace a faulty circuit breaker. |
| NO AC OUTPUT—GENSET RUNNING AND AIR DISCHARGING | Misconnected Generator or Voltage Regulator, Faulty Generator or Voltage Regulator | Check for proper generator and load connections (A.); Check voltage sense lead connections between the voltage regulator and Terminal Block TB1 (B.); Check electrical continuity and correct polarity between the Exciter Stator leads and the Voltage Regulator terminals (C.). If necessary, isolate the problem to the generator or voltage regulator using the procedure on Page 14; Test the generator stator, rotor and exciter windings and diode assembly as instructed if not accessible (D.). |
| NO OUTPUT OR AIR DISCHARGE — ENGINE RUNNING | 1. ON/OFF Switch OFF Turn the switch ON. 2. Disengaged PTO Engage the PTO. 3. Blown Fuse (F1) Replace with a 20 amp (yellow) blade-type fuse (Page 27). If the new fuse blows, check for ground faults in harnesses 338-4084, 338-4085 and 338-4087 and replace as necessary (Page 24, 25 or 26). 4. Hydraulic fluid leak Check for and repair any leaks in the system and refill as necessary (Page 13). 5. 12 VDC not available Check for 12 VDC at terminal 2 of the ON/OFF Switch (S1 on the Wiring Schematic, Page 27). Service as necessary. 6. Faulty ON/OFF Switch Turn ON the ON/OFF switch (S1) and check for 12 VDC at switch terminal 1 (Wiring Schematic, Page 27). Service as necessary. | |
| NO OUTPUT OR AIR DISCHARGE — ENGINE RUNNING (CONTINUED) | 7. Faulty Lead Harness Check for bent, corroded or missing connector pins and damaged leads in harnesses 338-4084, 338-4085 and 338-4086 and replace as necessary (Page 24, 25 or 26). 8. Faulty Pump ON/OFF Solenoid E1 Test and service as necessary (Page 11). 9. Faulty Pump Test and service as necessary (Page 11). | |
| NO OUTPUT OR AIR DISCHARGE—ENGINE RUNNING | ON/OFF Switch OFF; ON/OFF Switch was ON when the engine was started or the PTO was engaged; Disengaged PTO; Blown Fuse (F1); Hydraulic fluid leak; 12 VDC not available or polarity reversed | Turn the switch ON.; Turn the switch OFF and then ON.; Engage the PTO.; Replace with a 20 amp (yellow) blade-type fuse (Page A-4). If the new fuse blows, check for ground faults in harnesses 338-4084, 338-4085 and 338-4087 and replace as necessary (Page A-3).; Check for and repair any leaks in the system and refill as necessary (Page 3).; Disconnect connector J1 at the genset and check for 12 VDC across pins A and B and Positive (+) 12 VDC at pin A. See Page A-4. Service or reconnect as necessary. |
| NO OUTPUT—GENSET RUNNING AND AIR DISCHARGING | Faulty ON/OFF Switch; Faulty Lead Harness | Disconnect connector P2 at the genset and check for electrical continuity across pins A and B when the switch is turned on. See Page A-4. Replace a faulty switch.; Check for bent, corroded or missing connector pins and damaged leads in harnesses 338-4084, 338-4085 and 338-4086 and replace as necessary (Page A-3). |
| NOISY GENERATOR | Loose brush block, Loose fan, Worn rotor bearing, Misaligned rotor and motor | Tighten the mounting screw as necessary (Page 17), Tighten as necessary (Page 17), Replace as necessary (Page 17), Reassemble correctly (Page 17) |
| NOISY PUMP OR MOTOR | Air trapped in hydraulic fluid | Purge the air and refill the oil reservoir as necessary (Page 9). |
| OUTPUT VOLTAGE TOO LOW | Misadjusted frequency, Misconnected Genset Power Supply Cord, Shorted main winding, Shorted quadrature winding, Worn brushes and slip rings or shorted rotor winding, Faulty AVR | Adjust frequency as necessary (Page 14), Reconnect the genset power supply cord correctly at the vehicle AC distribution panel (Wiring Schematic, Page 27), Test and service main winding as necessary (Page 18), Test and service quadrature winding as necessary (Page 18), Test and service brushes and slip rings or rotor winding as necessary (Pages 17 and 18), Replace the automatic voltage regulator (AVR) (Page 18) |
| VOLTAGE TOO HIGH OR TOO LOW OR UNSTABLE | Wrong PTO speed ratio, Voltage misadjusted, Faulty Generator or Voltage Regulator | Change the PTO gear ratio if pump speed at engine idle or maximum engine speed falls outside the Min-Max pump speed range (A.); Adjust voltage and voltage stability as necessary (B.). If there is access to the terminals on the voltage regulator, use the procedure on Page 14 to isolate the problem; Test the generator stator, rotor and exciter windings and diode assembly if not accessible (C.). Replace the Voltage Regulator only if tests indicate that the generator windings and diode assembly are sound (D.). |
Fault codes and symptom→remedy steps extracted from this controller’s service/owner documentation; verify against the official manual before servicing. Aggregated from the service documentation of generator sets built on this controller.