GEN OVERVOLT
Gillette
Generator Overvoltage Condition
Controller displays GEN OVERVOLT or HIGH AC VOLTAGE; generator may shut down or open main breaker.
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Safety Warning
This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.
If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.
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Possible Causes
Faulty automatic voltage regulator (AVR), Incorrect AVR sensing wiring, Loose or broken voltage feedback connection
How to Fix / Troubleshooting
Safety first: Open the generator output breaker to isolate from the load. Turn OFF the generator and disconnect battery negative before opening the control panel. High voltage is lethal.
Steps:
- Visual inspection: Locate the AVR module in the Gillette generator control box or alternator terminal box. Inspect for burned components, discoloration, or melted connectors.
- Check sensing leads: Verify that the AVR sensing wires are securely connected to the correct generator output terminals as per the wiring diagram. Loose or miswired sensing can cause overvoltage.
- Measure no-load voltage: With a qualified person and proper PPE, start the generator with no load and measure line-to-line and line-to-neutral voltages. If significantly above nameplate (e.g., >10%), shut down immediately.
- Replace AVR: If wiring is correct and overvoltage persists, replace the AVR with the correct Gillette-specified part for your alternator model.
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Repair Difficulty
Hard
4/5
Required Part
Automatic Voltage Regulator
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