Generator overload light on or breaker keeps tripping? How to fix it

Try these first

1. Unplug everything from the generator.
2. Reset the tripped breaker. On an inverter, stop and restart the engine.
3. Let the engine run a few minutes with no load.
4. Plug in your biggest motor load first, such as the fridge or sump pump.
5. Wait for it to start and settle. Then add other things one at a time.
6. Note what you plugged in when it tripped. That's your clue.

Too much load in total

Symptom: It trips after you add one more thing, or the overload light stays on.

Why it happens: Every generator has a running-watt limit. Generac warns that overloading beyond that capacity can damage the generator and your devices. Honda's inverter shows it clearly: go over the rating, and the red overload light comes on. About four seconds later, power to the outlets shuts off, while the engine keeps running.

How to check and fix it:

1. Find the running watts on each appliance's label. If it lists amps, Champion's manual gives the formula: volts × amps = watts.
2. Add up everything you want to run at the same time.
3. Compare that with the generator's running (rated) watts, not its peak.
4. Cut back until you're under the limit. Run the space heater or the microwave, not both.

The calculator on this page does the math for common appliances.

A motor's starting surge

Symptom: It trips the moment a fridge, pump, air conditioner or power tool kicks on, even though the total looks fine.

Why it happens: Motors need a burst of extra power to start. Honda says most motorized appliances need more than their rating at startup, and the overload light may come on. It says that's normal if the light goes off within four seconds. Champion explains that tools like air compressors and saws can draw as much as three times their running load when starting. A generator's peak rating only covers that for a few seconds, until the motor gets up to speed. If you add that surge on top of everything else, the breaker trips.

How to check and fix it:

1. Champion's method: take the highest starting wattage of all your devices and add it to the total running watts. That's what the generator must handle.
2. Start the biggest motor first, while nothing else is running.
3. Never let two big motors start at the same moment. Champion's power management advice is to start one device at a time.
4. If the light stays on longer than four seconds on a Honda-type inverter, Honda says to consult your dealer.

The engine is cold or just started

Symptom: It trips right after starting, but works if you wait.

Why it happens: Generac says generators need to stabilize and warm up before you add appliances. Champion says to let the engine warm up for a few minutes after starting.

How to fix it: Start with nothing plugged in, wait a few minutes, then add loads.

A damaged cord or faulty appliance

Symptom: It trips when one particular item is plugged in, even a small one.

Why it happens: A short in a cord or appliance draws a big current. Champion lists "faulty cords or device" as a cause of repeated breaker tripping. Honda says the overload light also comes on for a short circuit in a connected appliance.

How to check and fix it:

1. Check every cord along its full length for cuts or tears. CPSC says the plug should have all three prongs.
2. Replace any damaged cord. Don't tape it.
3. Plug in the suspect appliance alone. If it trips a nearly empty generator, the appliance is faulty.
4. Use heavy-duty outdoor cords. CPSC says each cord's wattage rating should exceed the total wattage of everything plugged into it.

Overheating

Symptom: It runs fine for a while, then the overload light comes on or output stops, often on hot days.

Why it happens: Honda lists "inverter unit overheat" as a cause of the overload pattern, and says to check the cooling air inlet. Champion lists "insufficient ventilation" when a generator can't supply enough power or overheats.

How to fix it:

1. Stop the engine and let it cool.
2. Clear leaves, snow, covers or walls away from the air vents.
3. Give it space on all sides. Honda says to keep it at least 3 feet from walls and other equipment.
4. Restart and reduce the load.

The overload light blinks and won't clear

Symptom: On an inverter model, the overload light keeps blinking with nothing plugged in.

Why it happens: Honda says a continuously blinking overload light suggests an inverter fault.

How to fix it: Take it to a servicing dealer. There's nothing for you to reset.

When to stop and call a pro

Have it serviced if:

• It trips with nothing plugged in.
• The breaker won't reset, or it feels hot.
• You smell burning or see scorch marks near an outlet.
• An inverter's overload light blinks continuously.

If you're running home circuits, use a transfer switch or interlock installed by an electrician. Never plug the generator into a wall outlet.

Run it outdoors only, 20+ feet from the house: generator carbon monoxide safety.