Controller indicates ESTOP CIRCUIT OPEN or SAFETY CIRCUIT OPEN; generator will not crank.

Safety first: Ensure the generator is OFF and cannot auto-start. The safety loop protects against unsafe operation; do not bypass permanently.

Steps:

• Review safety loop diagram: Use the Gillette wiring diagram inside the control panel door to identify all devices in the safety chain (E-stop, low oil, high temp, door switches, etc.).
• Check each device: Inspect each switch or sensor in the loop for secure wiring and proper mechanical operation. Door interlock switches should depress fully when the door is closed.
• Continuity test: With power off, disconnect the safety loop from the controller and measure continuity across the loop. An open reading indicates a break; divide and conquer by testing segments until the fault is found.
• Repair: Replace any failed switch and repair broken wires with proper crimp connectors and heat-shrink tubing.