Industry
NA
Component
Hydraulic Manifold Plugs
Sealing Method
NPT

Modernizing Manifolds for Leak-Free Performance

The Challenge:

For years, NPT plugs were the default solution for hydraulic manifold sealing, chosen more out of habit than performance. However, these plugs were designed for one-time installation. Repeated removal and reinstallation led to persistent leaks and, worse, stripped threads that rendered entire manifolds unusable. After a customer raised concerns about fluid leakage and manifold damage, it was clear a change was needed.

The Solution:

To address both the leak issues and the damage caused by reinstallation, the company transitioned to Zero-Leak Gold® (ZLG) socket head -02 and -04 plugs. These plugs offer a secure seal that can be removed and reinstalled without compromising the integrity of the port. This decision not only addressed customer complaints but also introduced a more durable, long-term solution.

The Results:
  • Leak prevention: Eliminated leaks caused by the reinstallation of NPT plugs.
  • Product protection: Preserved manifold threads and prevented scrap.
  • Standardization: ZLG plugs are now standard on all new manifolds.
  • Customer satisfaction: Addressed complaints with a permanent sealing upgrade.
Industry
Military
Component
Hydraulic Manifold Plugs
Sealing Method
SAE

Solving Seal Failures in Military Ground Support Equipment

The Challenge:

A military airport reported recurring fluid leaks from hydraulic manifolds in their ground support equipment. The culprit: traditional O-ring-only SAE straight thread plugs that backed out during operation. Leaks on the equipment and surrounding floors posed serious safety risks and environmental concerns. Additionally, exposed O-rings were being spray-painted during finishing, shortening their lifespan and increasing the risk of failure.

The Solution:

To prevent further issues, the manufacturer installed -04 and -06 Zero-Leak Gold® (ZLG) socket head plugs. Unlike traditional designs, ZLGplugs feature an internal metal-to-metal primary seal with a protected backup O-ring positioned beneath the taper under the plug head. This design eliminated O-ring exposure to paint and removed the risk of vibration-induced loosening.

The Results:
  • Leak prevention: Eliminated hydraulic fluid leaks from manifold ports.
  • Safety improvement: Reduced slip hazards and environmental risks on airport grounds.
  • Enhanced durability: Protected O-ring extends service life by avoiding paint exposure.
  • Operational reliability: ZLG plugs remained secure under demanding military conditions.
  • Compliance support: Helped meet strict no-leak standards for ground support systems.
Industry
Automotive
Component
Hydraulic Cylinder
Sealing Method
ORB

Improving Uptime for Hydraulic Press Production

The Challenge:

Hydraulic presses employed in high-volume hydro-form production for the automotive industry faced ongoing plug failures. The current -12 socket head ORB J514 straight thread plugs, which relied solely on an O-ring for sealing, frequently backed out due to system pressure and vibration. Each failure necessitated an eight-hour shutdown to repair the leaking port, resulting in substantial production delays and increased repair labor costs.

The Solution:

The manufacturer replaced the O-ring only SAE plugs with -12 socket head Zero-Leak Gold® plugs (ZLGP). These plugs are specifically designed to resist loosening caused by vibrations, providing a more secure seal without necessitating changes to the existing port configuration. Their robust design ensures a consistent seal that remains intact, even during continuous high-pressure operations.

The Results:
  • Leak elimination: ZLGPs remained sealed without backing out under pressure.
  • Downtime reduction: Eliminated 8-hour shutdowns due to plug servicing.
  • Cost savings: Reduced repair labor and material waste.
  • Production stability: Maintained uninterrupted high-volume manufacturing.
  • Easy integration: Direct replacement for SAE J514 plugs without port modifications.
Industry
Forestry
Component
Hydraulic Cylinder
Sealing Method
SAE

Eliminating Shipment Leaks in Agricultural and Forestry Equipment

The Challenge:

Leaks in the fluid systems of agricultural and forestry equipment during shipment led to several issues, including environmental claims from transit and customs authorities. These leaks also caused paint contamination, damaging component sleeves. As a result, customer dissatisfaction increased due to the mess, the condition of the products, and the necessary cleanup efforts. The root cause of these problems was identified as the plastic plugs used in SAE ports, which failed to provide a reliable seal during painting and transportation.

The Solution:

To enhance reliability and prevent leaks at the ports, the plastic plugs were replaced with Zero-Leak Gold® (ZLG) socket head plugs. These precision-engineered plugs create a secure, leak-proof seal that remains effective during both painting and shipping. Importantly, they also allow for easy removal upon delivery.

The Results:
  • Leak elimination: Fluid system leaks during shipping were fully resolved.
  • Paint protection: No contamination of painted surfaces or damage to component sleeves.
  • Environmental compliance: No environmental claims or cleanup costs due to port leaks.
  • Improved customer satisfaction: Cleaner deliveries and higher confidence in equipment condition.
  • Operational efficiency: Removable ZLG plugs ensured hassle-free installation and servicing.
Industry
NA
Component
Drain / Fill Plug
Sealing Method
SAE

Eliminating Leaks and Contamination in Compressor Drain/Fill Systems

The Challenge:

SAE J514 style plugs with chemical sealant were used as drain/fill plugs on compressor systems. However, this sealant introduced a contamination risk during routine maintenance, particularly when service technicians neglected to properly clean the plugs and ports. Additionally, the chemical sealant required long curing times—up to four hours—delaying system pressure testing. Furthermore, system vibration and pressure often caused the plugs to loosen, and repeated removal of the plugs increased the risk of O-ring damage or nibbling, which further contributed to leaks.

The Solution:

Zero-Leak Gold® plugs (ZLGP) were installed directly into the existing standard SAE ports without any modifications. These plugs eliminate the need for chemical sealants, which reduces the risk of contamination and allows for immediate pressure testing after installation. ZLGPs are designed for repeated removal and replacement without damaging the O-rings, plug threads, or the port itself. Their secure fit resists loosening due to vibration and pressure.

The Results:
  • Leak elimination: ZLGPs eliminated leaks at all drain/fill locations.
  • Contamination prevention: Removed need for chemical sealants, reducing risk of system contamination.
  • Improved serviceability: Plugs can be removed and replaced without damaging O-rings or threads.
  • Time savings: Enabled immediate pressure testing without sealant cure delays.
  • Custom adaptability: Bleeder hole ZLGPs now available for specific compressor applications.
Industry
Truck
Component
Drivetrain
Sealing Method
NA

Achieving Leak-Free Performance in Heavy-Duty Truck Transmissions

The Challenge:

New regulations required heavy-duty truck engines to operate with greater fuel efficiency, lower emissions, and zero fluid leaks. This mandate applied not only to newly designed transmissions, including overdrive systems, but also to existing transmissions still in service. Traditional plugs used in drain and fill locations posed a risk of leaks, jeopardizing compliance and performance.

The Solution:

To meet these stricter standards, a -08 socket head Zero-Leak Gold® plug (ZLGP) was selected for use in the drain/fill locations of the new overdrive case. The same ZLGP is also being retrofitted into existing heavy-duty transmissions still in operation. Its reliable, leak-proof design ensures consistent performance across both new and legacy equipment.

The Results:
  • Leak elimination: No fluid leaks reported at ZLGP installation points.
  • Compliance support: Meets legislation requirements for zero-leak transmissions.
  • Retrofit-ready: Same solution applied to both new and existing transmission systems.
  • Improved uptime: Reduced risk of leak-related repairs and downtime.
Industry
Truck
Component
Drivetrain
Sealing Method
NA

Preventing O-Ring Debris and Leak Failures in Transmission Systems

The Challenge:

O-ring plugs in the transmission were backing out under normal operation. More critically, the O-rings were being damaged during installation or removal, with pieces detaching and falling into the transmission. This contamination required a partial teardown of the transmission to retrieve the debris—an expensive, time-consuming, and avoidable process.

The Solution:

Zero-Leak Gold® (ZLG) -04 socket head plugs were installed in place of the old-style plugs. The unique design of the ZLG plug eliminates O-ring nibbling and prevents thread damage during installation and removal. Their low-profile form also proved beneficial in tight spaces and improved overall fit within the transmission assembly.

The Results:
  • Leak elimination: No leaking plugs reported after installation of ZLG plugs.
  • Contamination prevention: O-ring integrity maintained—no debris entering the transmission.
  • Design efficiency: Low-profile ZLG plugs improved fit and access within tight transmission configurations.
  • Operational uptime: Eliminated costly and time-consuming transmission teardowns.
  • Supply chain support: Standard ZLG plugs integrate seamlessly with Kan Ban manufacturing process.
Industry
Truck
Component
NA
Sealing Method
NPT

Securing High-Temperature Exhaust Manifold Plugs for Light-Weight Trucks

The Challenge:

Traditional NPT plugs installed in exhaust manifolds often leaked at extremely high temperatures—up to 1,200°F. Additionally, these plugs tended to loosen over time due to vibration. When designing a new lightweight truck manifold, it was essential to create a plug that would remain secure under harsh conditions and could be easily removed for servicing without affecting performance.

The Solution:

To address these issues, a -10 socket head Zero-Leak Gold® plug (ZLGP) was installed without an O-ring. The ZLGP provides excellent resistance to vibration and thermal cycling while ensuring a secure and reliable seal, thanks to its design. Its metal-to-metal sealing mechanism guarantees that it remains in place even under extreme heat. Additionally, the plug can be removed and reinstalled as needed without damaging the threads or the sealing surface.

The Results:
  • Leak-free performance: Eliminated issues with NPT plug leakage.
  • High-temperature resilience: Withstood continuous exposure to 1,200°F.
  • Vibration resistance: Prevented loosening and back-out in high-vibration environments.
  • Service-friendly design: Plug remains removable without damage or seal failure.
Industry
Subsea
Component
NA
Sealing Method
SAE

Preventing Plug Failures in Subsea Robotic Trenching Equipment

The Challenge:

During subsea communication cable trenching operations, SAE-style plugs installed in the bearing housing of trench plows were becoming loose and backing out due to moderate vibrations. These trench plows function on the ocean floor using robotic systems and operate in ambient temperatures of around 35°C. Any leaks from the loosened plugs could lead to serious risks, including unplanned maintenance and costly project delays. Given the harsh environment, reliability is critical.

The Solution:

To resolve the issue, we installed Zero-Leak Gold® (ZLG) anodized aluminum -04 socket head plugs. These plugs offer a low-profile, secure seal that remains tight even under continuous vibrations. Their anodized finish enhances corrosion resistance, which is crucial in marine environments. Additionally, the plugs feature a metal-to-metal primary seal and an elastomeric backup, ensuring reliable, leak-free performance.

The Results:
  • Leak-free operation: No plug failures or fluid leaks reported.
  • Improved reliability: Eliminated vibration-related loosening and back-out.
  • Reduced downtime: Avoided costly maintenance interruptions and schedule delays.
  • Corrosion resistance: Anodized aluminum held up in harsh subsea conditions.
  • Long-term performance: ZLG plugs continued to perform in extended field use without issues.
Industry
Racing
Component
NA
Sealing Method
NPT

Reducing Costs and Improving Reliability for Racing Shock Absorbers

The Challenge:

In racing shock absorber applications, NPT plugs required Teflon-based sealant on the threads to prevent leaks. This added complexity and increased the cost of each installation by approximately $1.00 to $1.50. The plugs are crucial for containing hydrogen and shock oil, making reliable sealing essential for both performance and safety. The manufacturer sought a cleaner, more cost-effective solution that would maintain or improve sealing integrity.

The Solution:

The team developed prototype ports utilizing the SAE J1926 part configuration and installed -02 socket head Zero-Leak Gold® plugs (ZLGP) without any sealing compound. The innovative metal-to-metal seal of the ZLGPs, combined with an elastomeric backup, eliminated the need for thread sealants. This simplification of the assembly process allowed us to maintain high performance standards.

The Results:
  • Lower production costs: Eliminated need for Teflon sealant, saving $1.00–$1.50 per unit.
  • Clean assembly: No chemical sealant required, reducing contamination risks.
  • Leak-free performance: Maintained a secure seal without material degradation.
  • Simplified maintenance: Plugs can be removed and reinstalled without thread damage.
  • High customer satisfaction: No reported issues from end users.
Industry
Racing
Component
NA
Sealing Method
NA

Delivering Low-Profile, Leak-Free Plug Solutions for High-Performance Racing Engines

The Challenge:

In high-performance racing engines, space is limited. The existing plugs used in aluminum engine blocks had a high profile, which created clearance issues around the closely packed components. In addition to spatial concerns, the plugs needed to endure repeated removal and reinstallation without compromising their sealing integrity. This is crucial in racing environments, where frequent tuning and maintenance are standard.

The Solution:

To address concerns about clearance and performance, the team installed a variety of socket head aluminum and steel Zero-Leak Gold® plugs (ZLGP). Unlike traditional plugs that seal against the spot face, ZLGPs seal within the port, enabling a significantly lower profile. Their durable design allows for repeated use without damaging the threads or O-rings, ensuring consistent and reliable sealing even under the intense demands of competitive motorsports.

The Results:
  • Reduced plug profile: Enabled better clearance around engine components.
  • Leak-free performance: Maintained seal integrity despite frequent removal.
  • Improved serviceability: Allowed hassle-free installation and reinstallation.
  • Versatile application: Aluminum and steel ZLGPs adapted to multiple plug sizes.
  • Enhanced engine design: Supported more efficient layout of surrounding components.
Industry
Offshore / Oil
Component
Drain / Fill Plug
Sealing Method
NPT

Solving Repeated Leak Failures in Downhole Drilling Tools

The Challenge:

A downhole tool designed for oil filling in directional drilling applications experienced ongoing leakage issues. This tool operated in high-angle wells, with aggressive build rates of up to 90 degrees per 100 feet, and relied on NPT plugs. However, repeated removal and reinstallation of these plugs led to thread wear, resulting in oil leakage. Efforts to address the problem with chemical sealants were unsuccessful, introducing additional complexity and potential contamination risks in this precision drilling environment.

The Solution:

To resolve the issue, the port configuration was redesigned to comply with SAE J1926 standards. A -02 socket head Zero-Leak Gold® plug (ZLGP) was installed to replace the faulty NPT-style plugs. The ZLGP features a metal-to-metal seal and an elastomeric backup, eliminating the need for thread sealants. This design provides a more secure and repeatable seal, even with repeated use.

The Results:
  • Leak prevention: ZLGPg sealed reliably without chemical sealants.
  • Thread protection: No damage from repeated removal and reinstallation.
  • Simplified maintenance: Easy installation without the need for sealant or rework.
  • Proven performance: ZLGP successfully deployed across multiple tool setups.
Industry
Off-Highway
Component
Drivetrain
Sealing Method
SAE

Improving Reliability in Firefighting Gearbox Drain Systems

The Challenge:

SAE O-ring-only drain plugs used in firefighting gearboxes were prone to backing out, resulting in fluid leaks. Located in hard-to-reach areas, these drain plugs posed significant maintenance challenges, often requiring up to four hours to remove and reinstall the surrounding components during repairs. The recurring issue was due to both the instability of the plugs and damage to the O-rings, particularly under system pressures of up to 300 psi in the power divider PTO unit connected to the transmission.

The Solution:

To eliminate leaks and reduce service time, the firefighting equipment manufacturer replaced the troublesome SAE drain plugs with -04 socket head Zero-Leak Gold® plugs (ZLGP). These plugs feature a secure metal-to-metal seal along with an elastomeric backup O-ring, which offers enhanced resistance to pressure, vibration, and thermal cycling—common failure points of the previous plug design.

The Results:
  • Eliminated leaks: ZLGPs resolved leak issues under 300 psi conditions.
  • Prevented O-ring damage: Improved design eliminated wear during installation and operation.
  • Reduced service burden: Lower profile plugs simplified access in tight areas.
  • Enhanced equipment reliability: No plug failures reported since implementation.
Industry
Off-Highway
Component
NA
Sealing Method
SAE

Preventing Downtime in Hydraulic Systems with Zero-Leak Gold®

The Challenge:

Directional control valves are essential for reliably regulating hydraulic cylinders and motors. However, leaks from O-ring-only SAE -10 plugs, which often occur due to O-ring damage from the use of impact wrenches during installation, have led to frequent failures. These failures necessitate returning valves for repair, disrupting production schedules and increasing costs.

The Solution:

To resolve the issue, the manufacturer replaced the O-ring-only plugs with Zero-Leak Gold® (ZLG) -10 socket head plugs. The design of the ZLG plugs features a metal-to-metal seal along with a secure elastomeric backup, which helps prevent damage during installation. This change eliminates the risk of failures associated with the degradation of O-rings in the plugs.

The Results:
  • Leak-free operation: ZLGld plugs maintained a secure seal under hydraulic system pressures.
  • O-ring protection: Eliminated damage during installation with power tools.
  • Reduced downtime: Prevented valve failures and unplanned repairs.
  • Lower service costs: Eliminated labor and return shipping for plug-related repairs.
Industry
Off-Highway
Component
Drain / Fill Plug
Sealing Method
SAE

Preventing Oil Drain Plug Failures in Off-Road Equipment Differentials

The Challenge:

In compaction and material handling equipment, persistent leaks from differential oil drain plugs resulted in frequent breakdowns and costly downtime. The issue arose from vibrations caused by both the operation of the equipment and rough terrain, which led to the loosening of O-ring-only plugs over time. These failures raised reliability concerns, especially in challenging field environments.

The Solution:

To resolve the issue, the equipment manufacturer replaced the standard drain plugs with SAE straight thread magnetic Zero-Leak Gold® plugs (22S-S08M). These plugs offered a metal-to-metal primary seal with an elastomeric backup and a flush-mounted magnet to collect metal particles from the oil. The design also enabled repeated installation and removal without thread or O-ring degradation.

The Results:
  • Leak-free performance: No failures during a continuous 11-day vibration test.
  • Increased uptime: Eliminated breakdowns due to plug-related oil loss.
  • Contamination control: Magnetic feature captured harmful metal particles.
  • Standardized use: Now specified on all bills of materials across product lines.
Industry
Off-Highway
Component
Hydraulic Manifold Plugs
Sealing Method
SAE

Eliminating High-Pressure Hydraulic Leaks in Paving Equipment Manifolds

The Challenge:

A manufacturer of paving equipment experienced persistent leaks in their manifold cross holes due to the failure of old-style, O-ring-only SAE J514 plugs. Subjected to extreme pressure spikes—reaching up to 10,000 psi—as well as constant vibration and heat, the O-rings deteriorated over time. This degradation compromised the integrity of the seal, resulting in hydraulic fluid leaks that created performance, maintenance, and safety concerns in the field.

The Solution:

To address these issues, the manufacturer transitioned from traditional SAE J514 plugs to Zero-Leak Gold® (ZLG) socket head plugs in six sizes: -02, -04, -06, -08, -12, and -16. The ZLG plug’s low-profile design enabled tighter packaging within the manifold, while its metal-to-metal sealing surface with an elastomeric O-ring backup delivered superior sealing under extreme conditions.

The Results:
  • Leak elimination: ZLG plugs maintained seal integrity under 10,000 psi pressure spikes and constant vibration.
  • Improved durability: Metal-to-metal seal and O-ring backup resisted wear from heat and pressure.
  • Streamlined adoption: The Manufacturer implemented ZLG plug across all manifold applications.
  • Enhanced reliability: Eliminated maintenance issues tied to plug failures in paving equipment.
Industry
Military
Component
NA
Sealing Method
NA

Solving Fluid Leak Challenges for Military-Grade Hydraulic Components

The Challenge:

The existing O-ring-only plugs used in various hydraulic components were prone to leakage, creating reliability issues in critical military applications. With increasing mandates from the military demanding zero fluid leaks, any failure could lead to operational downtime, safety concerns, and costly maintenance. Ensuring a leak-proof seal was essential to meet these rigorous standards and maintain the integrity of hydraulic systems used in demanding military environments.

The Solution:

To address the leakage problem, an aluminum -05 socket head Zero-Leak Gold® plug (ZLGP) was selected as a direct replacement for the existing O-ring-only plugs. This plug offered a superior sealing design that could withstand the harsh conditions typical of military use. Despite not being officially listed on the military’s approved or certified plug list, the ZLGP demonstrated exceptional performance and reliability, making it an ideal solution for eliminating leaks and enhancing system durability.

The Results:
  • Leak elimination: ZLGPs completely prevented fluid leaks in all tested hydraulic components.
  • Superior performance: Outperformed plugs on the military’s approved list despite a lack of official certification.
  • Seamless interchangeability: ZLPGs fit directly into existing SAE plug ports without modifications.
  • Enhanced operational confidence: Met strict military no-leak mandates, reducing downtime and maintenance.
Industry
Military
Component
Drain / Fill Plug
Sealing Method
NA

Delivering Leak-Free Oil Pan Drain Plugs for Military Vehicles

The Challenge:

The oil drain plugs on military vehicles were leaking, which created significant operational, environmental, and maintenance challenges. Ensuring reliable sealing was vital due to the demanding conditions and the need to prevent contamination across all military branches.

The Solution:

Magnet-style -08 socket head Zero-Leak Gold® plugs (ZLGP) were installed to replace the standard plugs. These upgraded plugs have a strong metal-to-metal primary seal along with an elastomeric backup seal, which provides excellent leak prevention. Additionally, the integrated magnet captures metal particles, improving the system’s cleanliness and reliability.

The Results:
  • Reliable leak prevention: ZLGPs maintained a tight, durable seal in oil pan drain applications.
  • Effective particle capture: Integrated magnets trapped metal contaminants, simplifying maintenance.
  • Thread durability: Plugs removed and reinstalled repeatedly without damaging threads.
  • Cleaner system operation: No chemical sealants needed, reducing contamination risks.
  • Military-grade performance: Metal-to-metal and elastomeric seals provided maximum leak protection under harsh conditions.
Industry
Material Handling
Component
Hydraulic Cylinder
Sealing Method
NA

Preventing Hydraulic Oil Leaks in High-Heat Cylinder Applications

The Challenge:

In an oven dryer environment, plastic plugs used to seal hydraulic cylinder ports were expanding and deforming due to heat. This deformation caused hydraulic oil to leak onto the cylinder surface. The oil often went unnoticed before painting, leading to paint imperfections, costly rework, and customer dissatisfaction.

The Solution:

Zero-Leak Gold® plugs (ZLGPs) were installed to reliably seal the ports and prevent hydraulic oil leaks during the cleaning and painting process.

The Results:
  • Eliminated leaks: ZLGPs maintained a secure seal under high heat conditions.
  • Improved paint quality: Prevented oil contamination on cylinders, reducing rework.
  • Enhanced customer satisfaction: Fewer defects and improved product quality.
  • Broader adoption: Customer chose to replace all plastic cap plugs with ZLGPs
Industry
Material Handling
Component
Hydraulic Pump
Sealing Method
SAE

Eliminating Hydraulic Leaks in Forklift Pump Applications

The Challenge:

A forklift manufacturer was facing issues with hydraulic pump failures caused by leaks from O-ring-only SAE plugs. These plugs often backed out during operation, which compromised the performance of the pumps. Since the forklifts were used in environments with strict contamination controls, any fluid leakage presented significant environmental and operational risks.

The Solution:

In response, the forklift company requested that the pump manufacturer install Zero-Leak Gold® plugs (ZLGP) in all new pump assemblies and supply replacement plugs for units already in service. Customized metric-style ZLGPs were specified to ensure compatibility and performance.

The Results:
  • Leak elimination: Secure, repeatable sealing resolved plug back-out issues.
  • Improved reliability: Pumps functioned as intended with no hydraulic malfunctions.
  • Compliance assurance: Eliminated fluid leaks in sensitive operational environments.
  • Customer satisfaction: Confidence restored in the performance of both new and existing equipment.
Industry
Material Handling
Component
NA
Sealing Method
SAE

Eliminating Hydraulic Leaks in GPS-Guided Forklifts for Food Distribution

The Challenge:

In a high-throughput food and beverage distribution center, GPS-guided forklifts experienced hydraulic fluid leaks from SAE plugs that only had O-rings. These leaks were initially undetected and ultimately led to the contamination of consumable food products. As a result, a product destruction order was issued, along with fines from the FDA, resulting in significant financial and reputational consequences.

The Solution:

To prevent future failures, the manufacturer replaced the old SAE plugs with Zero-Leak Gold® (ZLG) socket head plugs in sizes -04, -06, and -08. The ZLG plug’s dual-seal design and taper-to-taper engagement offered a secure, vibration-resistant seal ideal for the dynamic operation of forklift mast and steering systems.

The Results:
  • Leak-free performance: Plugs no longer back out, even under constant vibration.
  • Regulatory compliance: Eliminated the risk of food contamination and FDA penalties.
  • Increased confidence: Cleaner, safer operation in food-grade environments.
  • Fleet expansion: The distribution center ordered 15 additional GPS-guided forklifts outfitted with ZLG plugs for use in facilities worldwide.
Industry
Forestry
Component
Hydraulic Manifold Plugs
Sealing Method
ORB

Preventing Plug Back-Out in High-Vibration Forestry Equipment

The Challenge:

A manufacturer of tree-cutting equipment was facing issues with plug failures caused by extreme vibration during operation. The traditional ORB plugs, which relied only on O-rings for sealing, frequently came loose, leading to hydraulic fluid leaks. These leaks not only compromised the appearance and reliability of the equipment but also raised environmental concerns, including the risk of soil contamination and potential violations of EPA regulations.

The Solution:

To resolve the issue, the manufacturer specified Zero-Leak Gold® plugs (ZLGP) in sizes -04 through -20 for all new equipment. Additionally, these plugs were used to replace any leaking plugs already in the field. The dual internal sealing design offered a secure, vibration-resistant solution, eliminating the need for external sealants or design modifications.

The Results:
  • Leak elimination: No leaks have been reported where ZLGPs were installed.
  • Improved reliability: Plugs stay securely in place despite heavy vibration.
  • Environmental protection: Reduced risk of contamination and cleanup liability.
  • Enhanced equipment appearance: No more unsightly fluid residue on machines.
Industry
Farm Equipment
Component
Hydraulic Cylinder
Sealing Method
NPT

Improving Hydraulic Cylinder Quality with Leak-Free Plugging

The Challenge:

A hydraulic cylinder manufacturer faced leakage and maintenance problems caused by hex head NPT plugs. To prevent leaks, the plugs were installed with a permanent chemical sealant, but this made removal extremely difficult. Plugs had to be heated for extraction, and cleaning both the plugs and ports added time and risk during reinstallation.

The Solution:

The manufacturer converted the cylinder ports to the SAE J1926 straight thread configuration and installed -06 and -08 socket head Zero-Leak Gold® plugs (ZLGP) . The dual-seal design of the ZLGP eliminated the need for chemical sealant and enabled easy, repeatable maintenance without damaging the threads or

The Results:
  • Leak-free performance: Eliminated fluid loss from plug ports.
  • Simplified maintenance: No sealant required, no heating necessary for removal.
  • Low-profile design: Improved fit and appearance of the finished product.
  • Product innovation: A new line of off-the-shelf agricultural cylinders is now being produced, highlighting the durability and serviceability benefits of ZLGPs.
Industry
Farm Equipment
Component
NA
Sealing Method
NA

Solving Leak and Contamination Issues in Magnetic Drain/Fill Applications

The Challenge:

A leading global manufacturer—ranked among the top three in its industry—was facing leaks and contamination problems with standard metric straight thread plugs used in hydraulic systems. The plugs frequently backed out and required chemical sealants to hold them in place. When the magnetic tip is removed for maintenance or cleaning, the sealant introduces a risk of system contamination.

The Solution:

The manufacturer replaced the standard plugs with Zero-Leak Gold® (ZLG) standard part number MS-S08M M22 x 1.5 socket head metric plugs featuring a flush-mounted magnet. These plugs provided a clean, repeatable seal without the need for chemical compounds, while maintaining the magnetic function to capture metal particles in the system.

The Results:
  • Leak-free performance: Eliminated the need for chemical sealants.
  • No contamination risk: Clean removal and reinstallation without introducing foreign material.
  • Improved identification: Metric size clearly engraved on the head for easy recognition.
  • Future standardization: The senior engineer confirmed the ZLG plugs with flush magnet will be specified in all future product designs.
Industry
Farm Equipment
Component
Hydraulic Manifold Plugs
Sealing Method
NPT

Eliminating Hydraulic Leaks and Maintenance Issues in Agricultural Equipment

The Challenge:

A manufacturer of agricultural machinery faced recurring issues with hydraulic leaks in valve blocks and cylinder assemblies. The use of NPT plugs with chemical sealant not only failed to prevent leaks but also introduced maintenance complications. Removing the plugs required heating due to the hardened sealant, making routine service difficult and time-consuming.

The Solution:

The engineering team converted the NPT ports to SAE J1926 straight thread ports and installed -06 socket head Zero-Leak Gold® plugs (ZLGP). With their dual internal sealing system, ZLGPs require no chemical sealant and offer secure, repeatable sealing even under pressure.

The Results:
  • Leak elimination: Replaced NPT plugs with ZLGPs for a clean, leak-free seal.
  • No sealant required: Simplified installation and removal without heat or residue.
  • Easier maintenance: Reduced downtime and service complexity.
  • Improved system reliability: Enhanced sealing performance in demanding agricultural applications.
Industry
Farm Equipment
Component
NA
Sealing Method
SAE

Solving Leak and Fitment Issues in Stacked Hydraulic Manifolds

The Challenge:

An agricultural implement manufacturer was experiencing hydraulic fluid leaks in equipment using stacked manifold systems. Unused ports were sealed with standard SAE J514 straight thread plugs, which backed out under system pressure spikes. The resulting leaks led to:

  • Environmental concerns due to soil contamination.
  • Increased maintenance and downtime.
  • Unsightly fluid buildup on the equipment.
  • Additional production complexity due to the high profile of the plug heads, which required counter-bores and recesses in both manifolds to accommodate fitment.
The Solution:

The manufacturer replaced the SAE plugs with socket head Zero-Leak Gold® plugs (ZLGP). The plug’s compact, low-profile design eliminated the need for counter-boring, while its dual internal seals prevented plug movement and fluid loss, even under pressure spikes.

The Results:
  • Leak-free performance: No hydraulic fluid leaks, even under pressure fluctuations.
  • Environmental compliance: Eliminated risk of soil contamination.
  • Lower maintenance costs: No need to disassemble manifolds to fix leaking plugs.
  • Streamlined manufacturing: Removed the need for additional machining on stacked manifolds.
  • Improved appearance: Cleaner, more professional-looking equipment.
Industry
Diesel Engine
Component
NA
Sealing Method
SAE

Preventing Oil Pan Leaks in Marine Diesel Engines

The Challenge:

A diesel engine manufacturer supplying power units to the marine industry faced a serious issue: oil pan drain plugs were backing out during operation, leading to fluid leaks. While limited to the oil pan, these leaks carried significant environmental liability—especially in marine environments where containment and cleanup are complex and costly.

The Solution:

To address the issue, the manufacturer replaced the SAE J514 straight thread plugs with Zero-Leak Gold® (ZLG) 22S-S05 non-magnet socket head plugs. These plugs feature dual seals that eliminate the need for chemical sealants and ensure a secure, repeatable seal—even under harsh operating conditions.

The Results:
  • Leak-free performance: Resolved oil pan plug failures and eliminated fluid leaks.
  • Enhanced reliability: Plugs maintain seal integrity without backing out.
  • Environmental protection: Reduced risk of spills in sensitive marine environments.
  • Maintenance-friendly: Plugs can be removed and reinstalled without damaging threads or seals.
Industry
Automotive
Component
NA
Sealing Method
NPT

Eliminating Oil Leaks in High-Volume Injection Molding

The Challenge:

A manufacturer producing 4 million molded plastic parts annually faced recurring issues with oil leaks in their injection mold. Operating at 320°F and cooled by circulating oil, the mold relied on NPT plugs that consistently failed due to thermal expansion and contraction. These leaks contaminated finished parts—rendering them unsalvageable—and created costly downtime, waste, and safety hazards.

The Solution:

To eliminate leakage, the NPT ports were replaced with SAE J1926 O-ring boss ports. A custom 3″ extension adaptor using Zero-Leak Gold® (ZLG) sealing technology was installed, along with a ZLG 22S-S03 socket head. This configuration ensured a robust, repeatable seal that withstands the demanding thermal cycling of the molding process.

The Results:
  • Leak-free operation: No more contamination of finished parts.
  • Reduced waste: Scrap rates significantly decreased.
  • Improved safety: Cleaner work environment for employees.
  • Less downtime: Reliable sealing eliminated the need for frequent maintenance.
  • Environmental compliance: Mitigated risk of oil exposure and related liabilities.
Industry
Automotive
Component
Hydraulic Manifold Plugs
Sealing Method
NA

Preventing Future Leaks in Oil Line Manifold Blocks

The Challenge:

A manufacturer developing a new oil line manifold block needed to ensure long-term sealing performance for a port designed to accommodate an oil pressure sensor. While leaks hadn’t yet occurred, past experience with SAE ORB plugs revealed that exposed O-rings were vulnerable to environmental degradation, eventually leading to failure.

The Solution:

To eliminate the risk of future leaks, the engineering team installed the MS-S01V metric Zero-Leak Gold® plugs (ZLGP). With its multi-seal design, the ZLGP protects the O-ring from exposure while providing two independent seals: a metal-to-metal taper and an internal elastomeric seal.

The Results:
  • Leak-free installation: Manufacturing confidence in a secure, long-lasting seal.
  • O-ring protection: Internalized design shields sealing elements from environmental damage.
  • Dual-seal performance: Added assurance with both metal and elastomeric seals.
  • Future-proof design: Eliminates the root cause of decay seen in conventional plugs.
Industry
Aerospace
Component
NA
Sealing Method
ORB

Ensuring Leak-Free Performance in Hydraulic Filters for Airfield Equipment

The Challenge:

A manufacturer developing hydraulic filters for mobile fluid carts and fluid power systems used in airfield operations needed to eliminate any risk of fluid leakage. Previous experience with standard ORB plugs—featuring only O-ring seals—revealed a critical issue: plugs had backed out under high-cycle test conditions, raising concerns about long-term reliability. Engineering sought a superior sealing solution for a new product launch, emphasizing performance and precision.

The Solution:

The team installed -04 hex head Zero-Leak Gold® plugs (ZLGP) as drain and fill ports in the new filter housings. To validate performance, the assemblies were submitted to an internationally recognized independent lab for endurance and burst testing.

The Results:
  • Zero-Leak: ZLGPs completed 1,000,000 pressure cycles with no reported leakage.
  • Superior performance: Traditional SAE plugs began to seep at 600,000 cycles.
  • Proven durability: Withstood burst tests up to 15,000 psi without failure.
  • Standardized solution: ZLGPs were adopted as part of the new filter design and will be included in future models.
Industry
Aerospace
Component
Hydraulic Manifold Plugs
Sealing Method
NA

Eliminating Re-Plating Requirements in NASA Manifold Applications

The Challenge:

During final inspection of nickel-plated manifolds intended for a NASA application, engineers identified a need to re-tap several existing ports. Under typical circumstances, re-tapping would also require a new spot face, which in turn would damage the nickel plating, triggering costly and time-consuming rework to replate the component.

The Solution:

NASA personnel, in collaboration with their manifold supplier, specified -06 and -08 Zero-Leak Gold® (ZLG) socket head plugs. Unlike standard plugs, the ZLG design does not rely on the spot face to form a seal. Instead, its two internal seals—a precision metal-to-metal taper and an elastomeric seal beneath the taper—create a leak-proof seal entirely within the port.

The Results:
  • No re-plating required: Avoided damage to the nickel finish by eliminating the need to machine a new spot face.
  • Zero-Leak performance: Delivered reliable, repeatable sealing in a high-stakes application.
  • Reduced rework and cost: Saved time and expense by streamlining the modification process.
  • Trusted performance: Chosen over traditional ORB-style plugs without requiring additional certification, based on proven test results.
Industry
Aerospace
Component
NA
Sealing Method
SAE

Securing Stainless Steel Manifold Plugs in Critical Aerospace Systems

The Challenge:

In high-stakes aerospace applications, even minor fluid leaks can cause major system failures. Traditional SAE J514 plugs were known to back out in cross-hole configurations—a risk that was unacceptable in this particular project, which involved powering actuators for mission-critical functions.

The Solution:

After reviewing the performance characteristics of the Zero-Leak Gold® plugs (ZLGP), the aerospace agency specified the -20 socket head version for use in the stainless steel power unit manifolds. Designed with two internal seals, the ZLGPs offered a secure, leak-free solution without relying on thread sealants or spot faces.

The Results:
  • No plug movement: ZLGPs stayed firmly in place, even in demanding cross-hole configurations.
  • Zero leakage: Passed all testing protocols without any fluid loss.
  • Mission-ready reliability: Validated for use in high-criticality aerospace applications.
  • Engineering confidence: Replaced legacy plugs with a proven, repeatable sealing solution.