Liquid Combustion Technology, Problem Definition

Liquid Combustion Technology

100 Roe Road	Phone: 864.660.8036
Travelers Rest, SC 29690	Fax: 864.834.6670
	E-mail: dougglass@lctllc.com

Oil Drain Tube Oil Seepage 9/28/2011

PROBLEM DEFINITION:

Oil Seepage from 35mm Drain Tube Reported by customer. After internal inventory audit, seepage was con- firmed. Further Investigative Analysis determined:

35mm Oil Tube Face (crush washer engagement area) does not meet surface finish drawing specification of 6.3um

Short Term Corrective Action:

LCT recommends increasing drain bolt torque to 23lb-ft to allow crush washer to fill excessive ridges/valleys caused by the out of specification surface finish:

 Capability study was conducted on 30pc of Oil Drain Tubes removed from inventory product  Engines were filled with oil and monitored over a 24hr period

 5pcs of the 30 were observed to have an oil witness mark below oil drain bolt (35mm drain tube side)

 Oil Drain Tubes were removed from engines and service Oil Drain Tubes (with correct surface fin- ish) installed and torqued and engines were placed back into inventory

 Removed Oil Drain Plugs were then torqued to 23lb-ft and pressurized in a submerged state to look for joint seal failure. No failures were observed after torque was increased to 23lb-ft

30pc Oil Drain Tube Samples

-Samples were torqued to 23lb-ft

-Samples were pressurized and sub- merged

-No leaks were detected

Long Term Corrective Action:

 Currently working with supplier to determine root cause of oil drain tube missing the facing operation  Will update with full 8D report once final root cause has been determined

Containment Activities:

 Inventory audits were conducted with product in South Carolina warehouse

 Product with May 25th date code (>15000 engine serial number) was discovered to have the “non faced” machining condition

 Product from August 6th (<8000 engine serial number in August) was discovered to have correct machined face surface area

 Total engine exposure based on the 5/30 statistical sample—5689

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