Mitch//pa
My unit is 2 years old and so far had 2 or 3 governors replaced under warranty. When doing the weekly exercise I get notified of the governor sensor fault. The first time they replaced the governor assy / throttle body. About 8 months later same fault they replaced the controller, all wiring and the governor.. The wiring and pins showed signs of corrosion also the same thing on the controller pins.. Dielectric grease was used to prevent the corrosion with the new parts, as there was no signs of grease on the original harness (you would think there should have been).. Well today it went to do the exercise and no go governor sensor fault.. This one is about 6-7 mths old.. I tried clearing it and no go the fault came back when she went to fire.. I then unplugged the controller two main harnesses all terminals and pins were good no signs of corrosion as well as the governor pigtail and pins.. Plugged the controller back in and she fired.. Let her run a while on QT quiet test and now she seems to be fine and restarting... So what do you think gives here??? Maybe by unplugging the controller it cleared the fault???
I purchased another new governor assy a year ago just to keep on the shelf in case of an emergency I didn't want to be s**t out of luck and down as I lost my trust in this unit
I think I'm still under warranty ...
I have done searches and can't find that this is a real problem with these units..
Any ideas???
TIA

P.s.
The last time it went down when they did the controller, harnesses / governor I installed my shelf unit and it fired right up.. Put the other one back on and no go...
Sorry for the long winded post
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UPS
Welcome to the forum, Mitch. The folks here need to have the model number to be able to offer the best advice. The serial number helps too, for those who have access to Generac's dealer site.
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Mitch//pa
Thanks UPS

Serial # 9005356
Model# 0055983
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Peddler
I have had a few 3-5 Nexis water cooled units that have given me an intermittent "gov Fault" shut down and they are extremely frustrating. I have replaced harnesses governors and controllers. My opinion is that there is something in the controller software/firmware that is causing the problem. On one unit I replaced the controller for another issue and it started with the occasional gov fault. It could be that it needs a longer hold off on something or there is just trash in the code somewhere. I have never had this fault solved by replacing anything but the controller and on one occasion I replaced it twice. This is one of those problems that the engineers just won't believe is a problem because it is so rare and tech support does not seem to have a good direct line to get problems solved. An example of this was the buzzing stepper on the air cooled Evo units they positively would not believe they had a problem until I sent one of the Sr. trainers a video of it while it was happening. Next thing you know there was a firmware upgrade to address it. Good Luck.
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Mitch//pa
Peddler;40656 wrote:
I have had a few 3-5 Nexis water cooled units that have given me an intermittent "gov Fault" shut down and they are extremely frustrating. I have replaced harnesses governors and controllers. My opinion is that there is something in the controller software/firmware that is causing the problem. On one unit I replaced the controller for another issue and it started with the occasional gov fault. It could be that it needs a longer hold off on something or there is just trash in the code somewhere. I have never had this fault solved by replacing anything but the controller and on one occasion I replaced it twice. This is one of those problems that the engineers just won't believe is a problem because it is so rare and tech support does not seem to have a good direct line to get problems solved. An example of this was the buzzing stepper on the air cooled Evo units they positively would not believe they had a problem until I sent one of the Sr. trainers a video of it while it was happening. Next thing you know there was a firmware upgrade to address it. Good Luck.



Peddler thank you for your detailed reply, it is greatly appreciated..
I plan to contact the installer today and see what they have to say.. I may also contact generac and open a case for this issue.. This defect is totally unacceptable and needs to be somehow resolved... Even though it's running now I do have the Mobil link notification showing the fault did occur...
I will post my findings and results as they happen

Thanks Mitch
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hedge54321
I've never seen a bosch gov go bad. it would probably out last the rest of the unit. Deffinatly with Peddler with bad controller.
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Birken Vogt
hedge54321;41236 wrote:
I've never seen a bosch gov go bad. it would probably out last the rest of the unit. Deffinatly with Peddler with bad controller.


I just replaced a Bosch throttle body on a 22 kw unit.

It would run smooth for a little while and then it would begin to bark like somebody just yanked the throttle open. It was throwing governor errors.

Not enough to really change the RPM much because the governor would catch it but I assume the throttle actuator had a sticky spot in it or something. I could never feel a sticky spot but replacing it fixed the problem 100%.
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Mitch//pa
I appreciate all the input...
UPDATE::
After contacting generac via email after my last post, I received a case number escalated to level III on August 9th 2016... The letter stated a representative would contact me... So far I have not heard from anyone...
Will keep this updated as it goes along...
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Peddler
I have continued to have this fault on some units even though I had replaced the Bosch throttle body unit but I have had others that did not repeat. This is the worst type of field service problem for anyone including Generac. Peddler
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Birken Vogt
I should add that the lurching/surging one referenced above did also have a control panel problem. One control panel would shut down with governor fault while the new one did not so maybe some of them are more sensitive to minor actuator problems?
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MarkJ
I am in the process of working on an ST02724ANAX (Nexus). I called generous support, and all they could throw me was to inspect both mag pickup (flywheel & cam) the cam mag pickup causes you to remove the enclosure, which is really time consuming. They also directed me (of course) to the Bosch. I did all of that, and still the same. The customer is 87 miles from my base shop one way, with no cell service. One thing that jumps out at me is; when the unit runs at full rpm for exactly 2 minutes, you will hear a slight bump increase in rpm (+1Hz) and voltage of course (+1V), and within 5 seconds shuts down in the "Gov Fault". I have concluded the problem is the controller. Any input will be appreciated.
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