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Old 07-09-2012, 05:12 PM   #1
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1999 Rexall Rexair class A-generac remote start

My problem is the Generac remote start on the dash will not crank or start the generator.If i go outside to the generator I can start it no problem and it runs like a charm.When it is running from starting it outside i can then go inside the coach and the auxiliary start switch is lit up and the hour meter is running.I can also shut the generator down from inside.There are 8 clips on the back of the switch.The 4 on the right of the switch are #1 top has 2 gray wires that seem to power the lite on the switch and the hour meter, #2 is green and is stop I think and the #3 is white neutral/ground and #4 is yellow start i think.The other bank only has a white wire on the #5 top prong.It is a generac q55g gn480 and the switch is a rocker type that allows the starter to engage and then release when it starts.Any help would be nice. I am by no means an electrician.
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Old 07-10-2012, 08:45 AM   #2
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It would help if you have a drawing of the switch setup. Check your service manual for you unit...maybe find it online. Then with an ohmmeter, you should be able to verify if the switch it working.

With Onan gensets, the switch grounds one of those wires to start it. Assuming Generacs do it the same way, check that you have a good ground at the switch, then that the switch is working. If that checks out, then move out to the genset compartment and disconnect the remote start connector and remeasure based on wire colors. If you've narrowed down which wire is grounded by the switch, then you can use a jumper wire and ground the terminal on the Generac that's suppose to start it. If that doesn't work, then you've probably got a bad control board. Your other tests will tell you if there is a bad ground connection, bad switch or open wire.
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Old 07-12-2012, 05:23 PM   #3
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I tested the switch with cotinuity tester and when the switch is rocked forward contact is made and when it is rocked rearward contact is made,so the switch should be alright.Looking at the diagnostic and repair manual i see a plug numbered 1 through 15 plugged into the control board.On this connector pin number 6 and 14 are #6 start and #14 stop using the switch on the generator.Pin #7 and #15 are #7 start and #15 stop for the auxiliary generator start.For some reason this is not happening.The stop side of the switch is working but the start side is not.Could I put a jumper wire between Pins #6 and #7 and maybe draw power from the generator switch to get the inside switch working?Then when I rock the switch forward from the inside switch i would bedrawing from start pins #6 and #7 and we know the outside switch is functioning properly.
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Old 07-13-2012, 12:25 PM   #4
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I tried the above with running a jumper wire and it did not work.Switch on gen works fine but front aux switch does not start gen ,will only turn it off.
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Old 07-13-2012, 01:23 PM   #5
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Had the same problem on my 97 bounder, found I had a corroded connector, cleaned all the connectors and everything worked fine.
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Old 07-13-2012, 01:46 PM   #6
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The Q55G has a 4 wire remote harness from the dash to the top right rear of the elec panel on the generator. Removing the panel cover will help to see better.

That plug fits in vertically and from back to front. The connector has 2 squeeze clips to unlock and remove. Get some good contact cleaner and clean both connections. Wires are red, blue, orange and black.

Failing that, I would think a faulty dash switch or connection. Possibly a broken wire under the coach somewhere.
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Old 07-13-2012, 02:15 PM   #7
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I can jump from pin #7 which is the start wire 17 to the aux remote and pin #12 which is common ground and get the gen to start.This tells me it is some where between the switch at front and the 4 prong plug at the gen.Going to take each wire off and clean and see if it just a ground not being made when the start button is depressed.
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Old 07-13-2012, 02:28 PM   #8
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Yep, not the rear conection, sounds like you're almost there!
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Old 07-13-2012, 03:48 PM   #9
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Pulled and cleaned all terminals and same condition-- no crank with remote switch.From 4 way connector on the gen that the front remote pluggs into ,i can jump from pin 3 to ground and start gen but cant do it at switch.
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Old 07-13-2012, 05:57 PM   #10
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One thing I've found with older electrical connectors is that sometimes I'll find that the terminal, when crimped on at the factory, sometimes is crimped onto the insulation where it's suppose to be on the bare wire. A small portion might indeed be crimped onto wire, but if it's not tight, or if it's corroded, you could get your symptoms.

The other possibility is that the 'Start' wire is broken somewhere between the dash and the genset.

Did you check for continuity at the connector down by the genset? With someone pushing the start switch? Or if you don't have help, you can run a jumper wire from 'common' to 'start' up at the remote switch.

Sounds to me like you're very close to solving this problem.
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