Component:
Oil Drum NPT Plug
Product:
Oil Drum
Case Number:
1019
Problem:
Due to a vibration by compaction equipment, the NPT plug on an oil drum backed out and leaked.
Use Description
The oil drum was used to hold bearing lubricant on compaction equipment.
Solution
The drum was designed to accommodate the SAE J1926 straight thread port. Zero-Leak Gold socket head plugs were installed.
Results
No leaks were reported once the ZLGP were installed. The ZLGP design made it possible to remove and install the plugs as needed without damaging the threads of the port or plug. It didn’t require a chemical sealant, and the O-ring remained intact during the process.
Post-Script
--
Component:
Manifold
Product:
Manifold Cross Hole
Case Number:
1020
Problem:
Old-style, O-ring only SAE J514 plugs leaked due to the deterioration of the O-ring caused by heat, vibration and pressure spikes of up to 10,000 psi.
Use Description
The SAE J514 plugs were installed in manifold cross holes. The manifolds were used in paving equipment of the construction industry.
Solution
The old-style, O-ring only plugs were eliminated and replaced with -02, -04, -06, -08, -12 and -16 socket head Zero-Leak Gold plugs. The ZLGP provided a low profile, as well as a metal-to-metal seal with an O-ring back-up seal.
Results
The manifold producer is using Zero-Leak Gold plugs across the board for all applications. The ZLGP have eliminated the concerns that existed with the previous plugs used.
Post-Script
62751
Component:
Cylinder - Hydraulic
Product:
Hydraulic Cylinder
Case Number:
1021
Problem:
It was determined that a low-profile, less-expensive plug would better suit this particular application.
Use Description
Plugs were used in the cylinder.
Solution
An engineering change incorporated the Zero-Leak Gold plugs into the product BOM.
Results
Zero-Leak Gold plugs are the "choice of the future" because of their quality and performance.
Post-Script
62421
Component:
Oil Pan – Drain Plug
Product:
Differential
Case Number:
1022
Problem:
The plugs in both of the oil drain pan differtial loosen due to vibration. The resulting leaks cause equipment break downs. The problems were most evident in the compaction and material handling equipment product lines.
Use Description
The oil pans used the old-style, O-ring only plugs. The operation of the equipment plus rough terrain caused vibration that resulted in the leaks.
Solution
We installed SAE straight thread magnet style Zero-Leak Gold plugs. 22S-S08M
Results
Extensive tests (continuously running for 11 consecutive days) conducted by the user with the ZLGP installed showed no leak failures. The magnets added an additional benefit by removing metal particles from the system. The ZLGP can be removed and installed repeatedly without damaging the threads of the plug or port nor the O-ring.
Post-Script
The ZLGP have become standard items on all BOM's. 63425
Component:
Directional Control Valve
Product:
Case Number:
1031
Problem:
The old-style, O-ring only SAE -10 plugs leak due to deterioration and destruction of the O-rings installed with the use of an impact wrench. Valves would have to be returned for repair.
Use Description
The old-style, O-ring only SAE -10 plugs are installed on directional control valves, which provided proportional control of both the movement and force capability of hydraulic cylinders and motors.
Solution
Zero-Leak Gold -10 socket head plugs replaced the SAE type plugs.
Results
The ZLGP did not leak and the O-rings were not damaged. The loss of valuable production time and costly repair labor due to leaking plug ports have been eliminated.
Post-Script
--
Component:
SAE O-ring Only Style Drain Plug
Product:
Drain Plug
Case Number:
1034
Problem:
SAE O-ring only drain plugs were backing out and causing leaks. The drain plug is located in a difficult position to access for repair. It was reported that it could take up to four hours to remove and reinstall components. O-ring damage was observed.
Use Description
The gear boxes are used in firefighting equipment. The SAE drain plugs caused leaks at 300 psi on the power divider which is a PTO unit connected to the transmission of the fire fighting equipment.
Solution
Zero-Leak Gold -04 socket head plugs were selected as replacements for the old SAE style.
Results
No leaks or O-ring damage has been reported.
Post-Script
Lower ZLGP profile than the SAE plug was an added benefit in the product design.
Component:
Drill Bit / Bearing Grease
Product:
Case Number:
1050
Problem:
NPT plugs would back or their threads were stripped due to 90,000 lbs. of load with impact loads up to 2 1/2 times that amount.
Use Description
NPT plugs were installed along with a chemical sealant and used to contain the grease that was used to lubricate the drill bit bearings.
Solution
The ports were modified to the SAE J-1926 configuration and -04, -05 and -06 Zero-Leak Gold socket head plugs were installed.
Results
The ZLGP didn’t back out. The engagement of the complimentary taper under the head of the ZLGP and the taper in the port prevented damage to both the threads of the plug and the port, in addition to providing the primary, metal-to-metal seal. The ZLGP were removable and could be installed repeatedly without any bearing contamination. No chemical sealant is used with ZLGP.
Post-Script
62411
Component:
Manifold Plug Port Leaking
Product:
Case Number:
1055
Problem:
An internationally known paving equipment company observed that the O-rings on the old-style, O-ring only SAE plugs in their purchased aluminum manifolds backed out and leaked.
Use Description
The aluminum manifolds were being used in a 3-4,000 psi environment. The manifolds were purchased as complete assemblies.
Solution
The manifold producer was informed of the SAE O-rings extruding and the plug ports leaking. One of the manifold producer's engineers had used Zero-Leak Gold plugs for some of their other customers. He sent a complete set of replacement Zero-Leak Gold plugs to be installed in the manifolds that had been delivered to his customer.
Results
The assorted sizes of socket head Zero-Leak Gold plugs were installed and there have been no more O-ring extrusions reported at the plug ports.
Post-Script
The paving company has requested that all future manifolds supplied to them have the Zero-Leak Gold plugs installed as part of the assembly process.