Controller displays “Overload” or “Overcurrent”; main breaker trips when large loads start on generator power.

Safety first: Open the main breaker and turn the generator OFF. Do not repeatedly reset a tripping breaker without finding the cause.

• Assess load: List major loads (HVAC, well pump, electric range, water heater). Compare total running and starting kW to the generator’s rating plate. Stagger start times or shed nonessential loads.
• Check for shorts: If the breaker trips immediately when closing under generator power, there may be a short in the load circuits. Isolate circuits at the transfer switch or main panel to identify the problematic branch.
• Inspect main breaker: Examine the generator’s main line circuit breaker for signs of overheating, discoloration, or mechanical looseness. Tighten mounting screws and line/load lugs.
• Test with reduced load: Start the generator, leave the main breaker open, then close it with only a few small loads connected. If it holds, gradually add loads while monitoring current draw.

If the breaker trips at low load or feels loose, it may be defective and should be replaced with a Kohler-specified breaker by a qualified electrician.