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# Zero Leak

## Sitemaps

- [XML Sitemap](https://www.zeroleak.com/sitemap.xml): Contains all public & indexable URLs for this website.

## Posts

- [Industry Insights](https://www.zeroleak.com/industry-insights/)
- [The Hydraulic Leak Myth: Why “A Little Leak” Still Costs You Big](https://www.zeroleak.com/industry-insights/plugs/the-hydraulic-leak-myth-why-a-little-leak-still-costs-you-big/) - For decades, hydraulic leaks have been accepted as a frustrating but inevitable part of industrial operations. Many engineers and maintenance professionals still believe that “a little fluid loss” is normal. Some even prefer the ongoing nuisance of hydraulic leaks to the perceived hassle or expense of installing zero-leak technology. But here’s the truth: Hydraulic systems
- [Leaking Profits: Why Ignoring Hydraulic Fluid Loss is Costing You](https://www.zeroleak.com/industry-insights/plugs/leaking-profits-why-ignoring-hydraulic-fluid-loss-is-costing-you/) - It’s easy to overlook hydraulic leakage. After all, what’s the big deal? A little fluid on the floor doesn’t seem like a crisis—until it is. In reality, hydraulic leaks are a slow, silent drain on your bottom line, chipping away at productivity, profitability, and even safety. The costs add up far faster than most operators
- [The Usual Suspects: Which Hydraulic Components Are Most Likely to Leak?](https://www.zeroleak.com/industry-insights/plugs/the-usual-suspects-which-hydraulic-components-are-most-likely-to-leak/) - When a hydraulic system starts leaking, the root cause often seems mysterious—until you take a closer look. The truth is, almost every component in a hydraulic circuit is vulnerable to leaks if not properly engineered or maintained. From piston seals to fittings to pipe plugs, leaks are a symptom of the system’s weakest link. But
- [Rethinking What “Zero Leak” Really Means](https://www.zeroleak.com/industry-insights/plugs/rethinking-what-zero-leak-really-means/) - If you’ve worked with hydraulic systems for any length of time, you’ve likely heard the term “zero leakage” used in a lot of different ways. Some define it as “less than a drop every few days.” Others say it’s “no visible oil at first inspection.” But at Zero-Leak Gold®, we believe it’s worth asking: Shouldn’t
- [Understanding What Causes Hydraulic Leaks—and How to Prevent Them](https://www.zeroleak.com/industry-insights/plugs/understanding-what-causes-hydraulic-leaks-and-how-to-prevent-them/) - If you’ve ever wondered why a hydraulic component leaks in one machine but performs flawlessly in another, you’re not alone. Hydraulic systems are complex, and the conditions that lead to leakage often involve more than just a faulty seal or fitting. The reality is that pressure spikes, vibration, and installation methods all play a role
- [Designing for Zero Leakage: It’s More Than Just the Right Parts](https://www.zeroleak.com/industry-insights/plugs/designing-for-zero-leakage-its-more-than-just-the-right-parts/) - Achieving a leak-free hydraulic system is possible—but it takes more than just choosing the right components. While plugs and fittings play a critical role, they’re only part of the equation. Design, installation, and ongoing maintenance all need to work together to keep systems running clean and leak-free. The good news? With the right practices in

## Pages

- [Zero Leak Gold](https://www.zeroleak.com/) - Zero-Leak Gold® hydraulic plugs and banjo fittings are the most reliable and cost-effective hydraulic fluid sealing options in existence. No leaks—guaranteed.
- [Case Histories](https://www.zeroleak.com/case-histories/) - Explore case histories by industry and component to see how Zero-Leak Gold plugs perform in the real world.
- [The Zero-Leak Gold Difference](https://www.zeroleak.com/request-a-sample/) - What’s the Zero-Leak Gold Difference? Read on to see why our plugs and banjos are the best in the industry, then request a free sample to try them for yourself! The Zero-Leak Gold Plug employs a very simple, geometry-reliant method of sealing for dependable zero-leak performance in all SAE J1926 and Metric ISO 6149 straight
- [Contact](https://www.zeroleak.com/contact/) - Have a question? Contact EPCO Products for more information on Zero-Leak Gold products, test reports and custom plug options.
- [O-ring Specs & Shelf Life](https://www.zeroleak.com/o-ring-specs-shelf-life/) - Find specifications and shelf life for the most common O-ring materials for reference in selecting or designing Zero-Leak plugs for your application.
- [Who We Are](https://www.zeroleak.com/who-we-are/) - EPCO is a leading manufacturer of products for the fluid power and marine industries. We're proud to have received the United States Senate Productivity Award and the OEMmie Award.
- [Materials & Finishes](https://www.zeroleak.com/materials-finishes/) - See materials and finish specifications of Zero-Leak Gold plugs and banjo fittings.
- [ZLG Burst Data](https://www.zeroleak.com/zlg-burst-data/) - The Fluid Power Institute (FPI) at the Milwaukee School of Engineering (MSOE) performed a burst test on Zero-Leak Gold Plugs (ZLGP). See their full report.
- [Quality](https://www.zeroleak.com/quality/) - EPCO’s Zero-Leak Gold Plugs are recognized for exceeding the expectations of its customers every day. See how we do it.
- [Port Dimensions](https://www.zeroleak.com/port-dimensions/) - See port dimensions and reference drawings to assist with design efforts. Zero-Leak Gold plugs are available for SAE J1926 and ISO 6149 standard ports.
- [MotorMate Assembly 2021](https://www.zeroleak.com/recruiting06/) - https://www.youtube.com/watch?v=joVCXvy5zIs
- [Zero-Leak Gold Plug Assembly](https://www.zeroleak.com/recruiting01/)
- [Marine Bow Eye Manufacturing](https://www.zeroleak.com/recruiting05/) - https://www.youtube.com/watch?v=jibGERqLDfU
- [Marine Bow Eye Assembly](https://www.zeroleak.com/recruiting02/) - https://youtu.be/p-byhoC4mCQ
- [Marine Shipping and Receiving](https://www.zeroleak.com/recruiting03/) - https://youtu.be/cOHEJLptfso
- [MotorMate Assembly](https://www.zeroleak.com/recruiting04/) - https://youtu.be/uO6mZw4CCV4
- [ZERO-LEAK GOLD VIDEO RESOURCES](https://www.zeroleak.com/videos/) - Discover Zero-Leak Gold® Plugs Unlike other sealing methods, Zero-Leak Gold® Plugs combine a primary metal-to-metal seal with an independent secondary O-ring back-up seal to create the most reliable and cost-effective fluid power plug option in existence today. Check out the videos below to learn more. Common Sealing Problems with SAE Fittings Existing old-style, O-ring-only SAE
- [How it Works](https://www.zeroleak.com/how-it-works/) - Zero-Leak Gold® plugs & banjo fittings effectively stop and seal hydraulic, manifold, oil and transmission leaks. See how they work.
- [Test Reports](https://www.zeroleak.com/technical-info/test-reports/) - Download the Fluid Power Institute test reports on the no-leak performance of Zero-Leak Gold hydraulic plugs and fittings.
- [FAQs](https://www.zeroleak.com/technical-info/faqs/) - Find answers to our most frequently asked questions about Zero-Leak plug technology and banjo fittings.
- [Troubleshooting](https://www.zeroleak.com/technical-info/troubleshooting/) - Find our troubleshooting checklist for leak cause and elimination, designed for applications with a Zero-Leak Gold Plug installed.
- [Sizes & Drawings](https://www.zeroleak.com/technical-info/sizes-drawings/) - See drawings and size charts for Zero-Leak Gold standard and magnetic plugs. Zero-Leak guarantee!
- [Torque Values & Tips](https://www.zeroleak.com/technical-info/torque-values-tips/) - See estimated torque values for Zero-Leak Gold Plugs and tips for determining torque values for specific applications.
- [Site Policies](https://www.zeroleak.com/site-policies/) - Privacy Policy, Website Terms of Use, Disclaimer. Find it all here.
- [ZLG Guarantee](https://www.zeroleak.com/zlg-difference/guarantee/) - See details on the lifetime guarantee for Zero-Leak Gold® plugs and banjo fittings.
- [Nomenclature](https://www.zeroleak.com/technical-info/nomenclature/) - See part nomenclature on Zero-Leak Gold hydraulic plugs and fittings.

## Products

- [Plugs](https://www.zeroleak.com/product/plugs/) - Zero-Leak Gold hydraulic plugs are a superior solution wherever standard ORB plugs are used. They are also guaranteed to never leak.
- [Banjo Fittings](https://www.zeroleak.com/product/banjo-fittings/) - Explore Zero-Leak Gold hydraulic banjo fittings—connectors and couplings for pipes, hoses and hydraulic applications. No leak guarantee!
- [Magnetic Plugs](https://www.zeroleak.com/product/magnetic-plugs/) - Explore Zero-Leak Gold magnetic drain plugs for applications including automotive oil and transmission drain plugs. No leak guarantee!
- [Custom Plugs](https://www.zeroleak.com/product/custom-plugs/) - EPCO can produce custom plugs—like transmission, oil & boat drain plugs—with the Zero-Leak Gold dual-seal design for no-leak performance. Get started today!

## Case Histories

- [Modernizing Manifolds for Leak-Free Performance](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/modernizing-manifolds-for-leak-free-performance/)
- [Solving Seal Failures in Military Ground Support Equipment](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/solving-seal-failures-in-military-ground-support-equipment/)
- [Improving Uptime for Hydraulic Press Production](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/improving-uptime-for-hydraulic-press-production/)
- [Eliminating Shipment Leaks in Agricultural and Forestry Equipment](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/eliminating-shipment-leaks-in-agricultural-and-forestry-equipment/)
- [Eliminating Leaks and Contamination in Compressor Drain/Fill Systems](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/eliminating-leaks-and-contamination-in-compressor-drain-fill-systems/)
- [Achieving Leak-Free Performance in Heavy-Duty Truck Transmissions](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/achieving-leak-free-performance-in-heavy-duty-truck-transmissions/)
- [Preventing O-Ring Debris and Leak Failures in Transmission Systems](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/preventing-o-ring-debris-and-leak-failures-in-transmission-systems/)
- [Securing High-Temperature Exhaust Manifold Plugs for Light-Weight Trucks](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/securing-high-temperature-exhaust-manifold-plugs-for-light-weight-trucks/)
- [Preventing Plug Failures in Subsea Robotic Trenching Equipment](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/preventing-plug-failures-in-subsea-robotic-trenching-equipment/)
- [Reducing Costs and Improving Reliability for Racing Shock Absorbers](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/reducing-costs-and-improving-reliability-for-racing-shock-absorbers/)
- [Delivering Low-Profile, Leak-Free Plug Solutions for High-Performance Racing Engines](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/delivering-low-profile-leak-free-plug-solutions-for-high-performance-racing-engines/)
- [Solving Repeated Leak Failures in Downhole Drilling Tools](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/solving-repeated-leak-failures-in-downhole-drilling-tools/)
- [Improving Reliability in Firefighting Gearbox Drain Systems](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/improving-reliability-in-firefighting-gearbox-drain-systems/)
- [Preventing Downtime in Hydraulic Systems with Zero-Leak Gold](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/preventing-downtime-in-hydraulic-systems-with-zero-leak-gold/)
- [Preventing Oil Drain Plug Failures in Off-Road Equipment Differentials](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/preventing-oil-drain-plug-failures-in-off-road-equipment-differentials/)
- [Eliminating High-Pressure Hydraulic Leaks in Paving Equipment Manifolds](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/eliminating-high-pressure-hydraulic-leaks-in-paving-equipment-manifolds/)
- [Solving Fluid Leak Challenges for Military-Grade Hydraulic Components](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/solving-fluid-leak-challenges-for-military-grade-hydraulic-components/)
- [Delivering Leak-Free Oil Pan Drain Plugs for Military Vehicles](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/delivering-leak-free-oil-pan-drain-plugs-for-military-vehicles/)
- [Preventing Hydraulic Oil Leaks in High-Heat Cylinder Applications](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/preventing-hydraulic-oil-leaks-in-high-heat-cylinder-applications/)
- [Eliminating Hydraulic Leaks in Forklift Pump Applications](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/eliminating-hydraulic-leaks-in-forklift-pump-applications/)
- [Eliminating Hydraulic Leaks in GPS-Guided Forklifts for Food Distribution](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/eliminating-hydraulic-leaks-in-gps-guided-forklifts-for-food-distribution/)
- [Preventing Plug Back-Out in High-Vibration Forestry Equipment](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/preventing-plug-back-out-in-high-vibration-forestry-equipment/)
- [Improving Hydraulic Cylinder Quality with Leak-Free Plugging](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/improving-hydraulic-cylinder-quality-with-leak-free-plugging/)
- [Solving Leak and Contamination Issues in Magnetic Drain/Fill Applications](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/solving-leak-and-contamination-issues-in-magnetic-drain-fill-applications/)
- [Solving Leak and Fitment Issues in Stacked Hydraulic Manifolds](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/solving-leak-and-fitment-issues-in-stacked-hydraulic-manifolds/)
- [Eliminating Hydraulic Leaks and Maintenance Issues in Agricultural Equipment](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/eliminating-hydraulic-leaks-and-maintenance-issues-in-agricultural-equipment/)
- [Preventing Oil Pan Leaks in Marine Diesel Engines](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/preventing-oil-pan-leaks-in-marine-diesel-engines/)
- [Eliminating Oil Leaks in High-Volume Injection Molding](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/eliminating-oil-leaks-in-high-volume-injection-molding/)
- [Preventing Future Leaks in Oil Line Manifold Blocks](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/preventing-future-leaks-in-oil-line-manifold-blocks/)
- [Ensuring Leak-Free Performance in Hydraulic Filters for Airfield Equipment](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/ensuring-leak-free-performance-in-hydraulic-filters-for-airfield-equipment/)
- [Eliminating Re-Plating Requirements in NASA Manifold Applications](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/eliminating-re-plating-requirements-in-nasa-manifold-applications/)
- [Securing Stainless Steel Manifold Plugs in Critical Aerospace Systems](https://www.zeroleak.com/industry-insights/zlg-difference/case-histories/securing-stainless-steel-manifold-plugs-in-critical-aerospace-systems/)

## Categories

- [Plugs](https://www.zeroleak.com/industry-insights/category/plugs/)
- [Custom Plugs](https://www.zeroleak.com/industry-insights/category/custom-plugs/)