Generator Overload Causes, signs, effects and fixes

How to Fix an Overloaded Generator

Generator overloads can be caused by a variety of factors. Some generator models are more prone to overload than others, so it’s important to know the causes and how to prevent overloads if you’re using a generator. This blog post will discuss generator load, generator types, and show you how to avoid generator overloads in general.

When your generator is overloaded, remove all the electronics connected to it then hit the circuit protector button after which you press the Overload Reset Button to correct its load. If the generator has been overloaded for a while before you notice the issue, always use the Overload Reset Button before you use it again.

Be careful with an overloaded generator given that the generator may be hot and the overload might have caused damage to it. You can always call a generator repairman in case you need professional help with your generator problem. Being aware of the causes of generator overload is important because an overloaded generator can lead to serious injuries or death due to electrocution.

What happens if you overload a generator?

When a generator is overloaded, it will stop powering whatever it is currently running and go into an overload situation. This is often a tripped circuit breaker or the generator going off. An overload occurs when the electronics connected to the generator need more power than the generator is currently providing.

Power generators are designed to be overloaded temporarily, but only for a short time. If the generator continues operating when overloaded, there’s a chance of damage or fire occurring because some parts may not function as intended if they’re being overworked.

Some signs of an overloaded generator include the following:

  • The circuit breaker will trip when the generator is overloaded.
  • The generator will shut off.
  • The generator’s cooling fan may stop turning or become overly loud. You’ll hear a humming noise from the generator, which is an indicator that it could be overloaded. The sound can sometimes get louder or change pitch if the overload continues (which means your generator needs to be turned off).
  • There might also be smoke coming out of vents on top of the generator and/or you might see sparks or flames shooting from under its cover as well. This all indicates something has gone wrong with your generator due to being overworked.
  • The generator might also get overly hot as well.
  • If the generator is supplying power to lights, you might notice the lights changing in intensity or even going off and on which is a clear sign that it’s struggling to support the load.
  • Soot in the exhaust gases.

With any one or a combination of these signs, you’ll be sure that the generator is being overloaded by the connected electronics.


Why Generator overload with nothing plugged in?

At times, the generator might indicate the overload light or even shut down when there is nothing plugged in. This often occurs when the generator has run for a while without a load. It’s not a common problem but can occur if you run your generator for long without a load.

In such a case, you might need to reset the generator. To reset the generator, turn off all power and then restart it. You should also use the overload reset button to reset the generator before restarting it. This time, once it stabilizes, plug in a load.

If the generator keeps on shutting down or showing a warning sign without a load, it could be faulty and in need of a fix from an expert. Let an engineer, preferably from the generator’s manufacturer, come to fix it.

How to fix Overloaded Generator

Once you notice that your generator is overloaded, follow these steps to fix it:

  1. First, disconnect all electrical equipment connected to the generator.
  2. Next, before resetting the circuit breaker, determine if the overload condition was because of exceeding the equipment’s rated load capacity.
  3. You then press and hold the rest button for at least one second to restart the generator.
  4. If the overload warning has gone off after the restart, reconnect the electrical appliances making sure you don’t surpass the generator’s output in the process. If the overload warning light is still visible even after the reset, you need to have the generator fixed since it might be something else and not an overload.

Sometimes, the problem isn’t overloading but the generator has a shortcut which turns on warning lights. In this case, the generator needs to be replaced.

Once you’ve fixed your generator and it’s been running without warnings for a few days, consider having an electrician come to inspect the generator.

This will help ensure that there are no problems with the generator or any cables connecting it to other devices in your home which could lead to another overload situation later on if left unchecked.

Tips to avoid Overloading the generator

If you have experienced overloading in your generator, you can avoid it as follows:

  • Never load the generator beyond the amount of power it can produce and then operate it at maximum output.
  • Avoid generator overload by using the generator’s start/stop controls to match generator load and demand, which will provide a more stable power supply.
  • Use generators with automatic voltage regulation (AVR) that can adjust automatically when voltage drops or spikes. Generators without AVR have a higher risk of getting damaged from overloading than those with this device.
  • If you must run all the appliances at once and you keep overloading your generator, go for a larger generator with a higher capacity.
  • If you’re experiencing generator overload, use a larger generator with higher capacity. If your generator can’t be repaired and it’s under warranty, contact the manufacturer for professional advice on how to fix electrical problems.
  • Follow their instructions on how to use the generator correctly and make sure that any circuits are properly rated before connecting them directly into an outlet box. You should also never tighten connections excessively when adding power cords because this is likely to damage circuitry within the generator or cause heat buildup due to improper ventilation of components.
  • If you replace fuses and circuit breakers, always use the same quality and rating as the ones you’re replacing.
  • When calculating the amount of power needed to run some appliances, check to see if they have both running and starting wattages. Appliances such as furnaces, fridges and others require more power to start (starting wattage) than what they need to run (running wattage. Make sure your generator meets the starting wattage at least for each one.

If your generator is overloaded and you can’t stop it, it can explode or even damage the appliances connected to it. With the above precautions, you can always prevent overloading and keep it in good condition. If your generator is overloaded and can’t be fixed, contact your generator’s manufacturer for professional advice.

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