Generator Leaks Oil: Why Does It Happen and How to Solve It?

Oil leakage of the generator is caused by sump plug seal deformation, loose oil filter, worn cranks, valve cover seal damage or blow-by blockage. Oil leakage requires urgent intervention as it can cause the engine to wrap the bearing (engine locking) without oil.

The Main Causes of Oil Leakage in the Generator

Worn or Improperly Installed Oil Filter: In periodic maintenance, the filter is not fully tightened, the old seal surface is not cleaned or the double seal remains, oil gushes under pressure.

Crankcase Plug and Flake Deformation: Leaving the oil drain plug loose or not renewing the copper/aluminum sealing washer in all maintenance causes dripping from the base.

Crank Front and Rear Seal Wear: Hardening of the oil seals around the engine shaft causes the generator running at high revs to flow oil from behind the flywheel housing or pulley.

Rocker (Valve) Cover Gasket: Roasting the cork or rubber seal on the engine top cover from high temperature causes oil to sweat and flow towards the outer surface of the engine block.

Crankcase Aeration Valve Blockage: When the excessive pressure inside the crankcase cannot be released, it pushes the oil in the engine through the gasket or felt where it finds the weakest.

Turbocharger Oil Pipes: In turbocharger diesel generators, the high pressure oil supply to the turbo and the looseness in the return pipes leak oil directly into the hot exhaust line.

Oil Leakage Detection and Solution Steps

Determine the Leak Point: Stop the generator and wait for it to cool down. Clean and dry the engine block with degreaser spray. Run the generator without load for 5-10 minutes and observe where the first oil trail comes from.

Check Filter and Drain Plug: If the leak is around the filter, bring the filter to the appropriate torque manually or with the filter switch. Check the crankcase plug and torque it by replacing the washer if necessary.

Measure the Oil Level: Check the oil stick of the generator after the leak. If the level is below the ⁠MIN⁠ line, absolutely do not start the engine; in viscosity in accordance with manufacturer standards (e.g. 15W-40) add oil.

Replace Gasket and Felt: In case of tears in the rocker cover or crancase seal, remove the part and assemble it with the original new gasket with the support of the liquid seal.

Risks That Oil Leakage Can Cause

Bearing Wrapping and Engine Locking: Oil-free moving parts overheat with friction, causing the piston and crankshaft to lock the engine to be completely scrapped.

Fire Hazard: Engine oil dripping on hot surfaces above 400°C such as a turbo or exhaust manifold may catch fire.

Low Oil Pressure Alarm: When the oil pressure sensor detects a critical pressure drop, the generator suddenly switches to an emergency stop while it is in charge, leaving the system de-energized.