Michael Hart
Hello,

I have a new (5 months old) 60kw 2.4L natural gas Generac Protector model RG06024ANAX serial 3003015322. A little history about the generator. It worked initially but then stopped working with an "RPM Sense Loss" error message. I called Waukesha-Pearce and after 3 trips they found grass inside the gas solenoid blocking it from closing and flooding the engine. In the process of repairing it they broke off the end of the Cam sensor and replaced it. They also replaced the Evolution controller. They charged me $2,386 for their work because of the grass they found inside the gas solenoid that isn't covered by the warranty. It worked (exercised only) for about a month after they finished.

Now it turns over for a couple of seconds and just when it sounds like it's starting it stops with Alarm Error Code 2602 Ignition Fault.

I have checked and adjusted the fuel pressure to 10 inches of water column (spec is 5-14"WC). I purchased the diagnostic manual from Ziller and Error 2602 is listed as Crank Circuit (External Module). It refers me to Problem 38 (Missing Cam Pulse) or Problem 39 (Missing Crank Pulse). I've measured the resistance of the Cam and Crank Sensors and they are both 1,000 ohms like their supposed to be. I also checked the adjustment of the cam sensor and it's .015" like it's supposed to be. I tried unplugging the Crank/Flywheel sensor and then I get an RPM Sense Loss. Since this is a different error I don't think this sensor is the issue. I don't have the breakout harness to check the adjustment on it, but I could get it.

I also have a slow gas leak inside the generator. If my math and meter reading is correct it's about 1.2 cubic feet of gas per hour. I have taken the solenoids off and made sure that no more grass is caught in the plungers. It has the 0F5022 gas solenoids. I've been reading and have thought about upgrading the solenoids and plungers to to the 0J7137 & 0J8315A.

I would appreciate any help or suggestions.
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Peddler
My first suggestion would be to get a different dealer as the original fault probably had nothing to do with what they are telling and the cam sensor and controller change were most likely un- warranted. The likely problem would be the ignition control module which could be a problem with the connection or the module itself any of which should be under warranty. There is an LED that flashes on the back of the ignition module under the tan cover that may give some guidance. If the grass was the cause of the problem you would have had a low gas pressure alarm in the history.
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Michael Hart
Hi Peddler, Thank you for your quick response. Yes I am definitely looking for a new dealer. Waukesha-Pearce won't get anymore of my money. I'm in North East Texas. I'm thinking of using the Generator Superstore out of Tyler, TX, but if anyone else knows a dealer in my area please let me know.

I didn't see an external ignition control module. I think it may be inside the Evolution controller.

Is there a possibility that the PRAM group wasn't set right when they changed out the controller? It's set to 16, but I can't find what it should be. Also the voltage group is set to 14 and volts per hertz is 4. I'm not sure what these things do, but I can't verify they are correct. It did work for a month after they changed the controller though.

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BrentB
Those settings are correct for 240V single phase unit on NG or LP. Ignition is in the PCB.
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BrentB
Manual points to PCB.
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Peddler
Well in August someone submitted two claims on this unit one for a controller and one for a new engine mounted alternator. I don't know if this is the same thing they are charging you for but it seems strange. You are correct that there is not an ignition module on this unit. The controller needs to be set correctly for voltage engine and operating parameters which could be the trouble. There are a lot of variable here but in any case this should be covered under warranty. I would get in touch with Generac and ask them why the service wasn't covered because the grass in the solenoid would have shown up in the fault history if it were anything but BS.
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BrentB
You need to check for .4 Volts during cranking on the RPM sensor. 1000 ohms is correct, but if something is blocking the tip of the MPU, the voltage won't be produced. Could be as simple as a metal shard stuck to the tip of the MPU, or too big of a gap. Only way to rule this out is with the breakout harness, or back probe the J plug connections.
I think it would be best to get Generac customer service involved, as all this should be being handled by a Factory authorized dealer, under warranty.
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BrentB
Peddler;n59799 wrote:
Well in August someone submitted two claims on this unit one for a controller and one for a new engine mounted alternator. I don't know if this is the same thing they are charging you for but it seems strange. You are correct that there is not an ignition module on this unit. The controller needs to be set correctly for voltage engine and operating parameters which could be the trouble. There are a lot of variable here but in any case this should be covered under warranty. I would get in touch with Generac and ask them why the service wasn't covered because the grass in the solenoid would have shown up in the fault history if it were anything but BS.


Looks like the claim may have been denied as it stated this claim requires a control number!
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Peddler
I see that now but it shouldn't be a problem for him to get a control number if they were legitimate claims. I don't understand why they would not have filed a normal warranty to include the gas solenoid but all this seems slimy to me. The gas leak is a problem as well if it is in fact leaking. Who did you buy this unit from? Have you paid the other dealer? Again rather than have us bat around the hundreds of things it could be, it is under warranty, have Generac fix it!
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cookelec
Something doesn't add up. The RPM sense loss could very well have been a dead battery. But the charges are way out of line with the warranty claims filed. You need to find another dealer and call Generac customer service and discuss this with them. Have a copy of your bill ready to submit to them. As already stated, this should all be covered by warranty and Generac needs to have a qualified service dealer repair it. You should not try the repairs yourself as it may void the warranty.
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UPS
If there was actually grass in the gas valve, it probably got into one of the pipes at the original installation. Depending on who did the install, maybe replacing the gas valve would not be covered under warranty, but the other problems all should be.
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