Original SANY Fuel Injection Pump Flange 160102130003A100 Construction Machinery Parts

The genuine SANY parts reference 160102130003A100 is the Fuel Injection Pump Flange, a precision‑machined mounting bracket that secures the fuel injection pump to the engine block in SANY heavy‑duty diesel engines. The 160102130003A100 injection pump flange ensures accurate pump alignment, correct gear backlash, and leak‑free sealing of the pump mounting interface.

Manufactured from high‑strength ductile iron with a corrosion‑resistant zinc‑nickel coating, this flange withstands vibration and thermal cycling. Each 160102130003A100 unit is 100% inspected for flatness, bolt hole positions, and surface finish, guaranteeing reliable pump mounting in SRT dump trucks, SY excavators, SW wheel loaders, and motor graders.

Fuel Injection Pump Flange

Фланец ТНВД

Brida de la bomba de inyección

Fuel Injection Pump Flange

Фланец ТНВД

Brida de la bomba de inyección

Fuel Injection Pump Flange

Фланец ТНВД

Brida de la bomba de inyección

Material and Design of Fuel Injection Pump Flange 160102130003A100

The fuel injection pump flange 160102130003A100 is cast from ductile iron (GGG40 / EN‑GJS‑400‑15), offering tensile strength of 400 MPa and elongation of 15%. The flange has a rectangular shape (120 mm x 100 mm) with four mounting holes (10.5 mm diameter) on a 100 mm x 80 mm bolt circle. A central bore of 45 mm diameter accommodates the pump drive shaft. The flange thickness is 18 mm.

The flange features an integral O‑ring groove (4.5 mm deep x 5.0 mm wide) machined into the engine block side for an O‑ring seal (SANY 160102130003A099). The pump mounting side is precision‑ground to a flatness of 0.05 mm to ensure leak‑free sealing. Two dowel pin holes (8 mm diameter) are provided for accurate alignment. The flange also includes four tapped holes (M10) for pump attachment.

Surface treatment is zinc‑nickel plating (8-12 µm) with black trivalent passivation, providing 500 hours of salt spray resistance (ASTM B117). The flange is designed to withstand a maximum torque of 200 Nm from the pump drive and a clamping force of 50 kN from the mounting bolts. The weight is 2.8 kg.

All 160102130003A100 flanges are 100% CMM‑inspected for flatness, bore diameter, and bolt hole positions. A sample from each batch is hardness‑checked (150‑210 HB) and fatigue‑tested (1 million cycles at 120% of max load). A laser‑etched batch code on the flange provides full traceability.

Function of Flange 160102130003A100 in Fuel System

The fuel injection pump flange 160102130003A100 provides a rigid mounting interface between the injection pump and the engine block. It ensures that the pump drive shaft is precisely aligned with the engine gear train, maintaining correct gear backlash (0.08‑0.12 mm). A warped or misaligned flange will cause gear noise, accelerated wear, and incorrect injection timing.

The flange also supports the pump housing against the torque pulses generated by the plungers. A cracked flange can allow the pump to shift, causing timing drift and eventual pump seizure. The integral O‑ring groove seals the interface, preventing fuel or oil leakage. The dowel pins ensure repeatable alignment if the pump is removed for service.

On SANY D07/D09/D12 engines, this flange is bolted directly to the gear case cover. It is typically replaced only if damaged (cracked, warped, or corroded). Always use a new O‑ring and new mounting bolts when installing a replacement flange.

Compatible SANY Models & Interchange Information

The fuel injection pump flange 160102130003A100 is used on SANY D07, D09, and D12 series diesel engines. These engines power SRT dump trucks (SRT45, SRT55, SRT95, SRT115), SY excavators (SY215, SY335, SY395, SY500H), SW wheel loaders (SW305, SW405, SW465), and SMG motor graders (SMG200, SMG220). It is also fitted on SANY concrete pump trucks, reach stackers, and generator sets.

The flange has a 45 mm bore and four M10 mounting holes on a 100 x 80 mm pattern. Always verify the original flange dimensions. When ordering, specify 160102130003A100 to receive the correct casting, flatness, and bolt pattern.

For fleet maintenance, stock genuine 160102130003A100 flanges. Aftermarket flanges often use gray iron (brittle) or have poor flatness, causing leaks and alignment issues. Genuine SANY flanges guarantee ductile iron construction, precision machining, and corrosion protection.

Technical Specifications – Fuel Injection Pump Flange 160102130003A100

Proper Installation of Flange 160102130003A100

Before installing the flange 160102130003A100, clean the mounting surface on the gear case cover. Install a new O‑ring (SANY 160102130003A099) into the groove. Place the flange against the engine block, aligning the dowel pins. Hand‑start the four M10 mounting bolts (grade 10.9). Tighten in a diagonal pattern to 45 Nm.

Check the flange flatness after tightening using a straight edge – maximum deviation 0.05 mm. If the flange is warped, remove and inspect the gear case surface. Install the injection pump onto the flange using four M10 bolts (grade 12.9) and torque to 50 Nm. Rotate the engine by hand to verify smooth pump rotation and no binding.

Never reuse an old flange that is cracked or corroded. Always use new mounting bolts. Store flanges in a dry, clean environment. Use only genuine SANY flanges for guaranteed fit and reliability.

Symptoms of a Damaged Flange 160102130003A100

A damaged 160102130003A100 flange will cause fuel or oil leaks at the pump mounting interface. You may see fuel weeping from between the flange and the engine block. A warped flange will cause gear noise (whining) from the pump drive as the gear backlash becomes excessive. A cracked flange may allow the pump to vibrate, causing timing drift and poor engine performance.

If the O‑ring groove is corroded or damaged, the seal will leak. Corrosion (red rust) on the flange indicates coating failure; replace the flange. A flange that has been over‑torqued may be cracked around the bolt holes. During disassembly, inspect the flange for cracks using dye penetrant.

During preventive maintenance (every 8,000 hours), inspect the flange for flatness and corrosion. Replace the flange if any damage is found. Use only genuine SANY flanges for replacement.

Quality Assurance & Full Traceability for 160102130003A100

Every fuel injection pump flange 160102130003A100 is manufactured in an IATF 16949 certified facility. The casting is X‑ray inspected for porosity, then heat‑treated and machined. Each flange is 100% CMM‑inspected for flatness, bore diameter, and bolt hole positions. A sample from each batch is fatigue‑tested (1 million cycles at 120% of max load) with no crack propagation.

Zinc‑nickel coating thickness is verified using XRF, and salt spray testing (500 hours) is performed on a sample. A laser‑etched batch code on the flange provides traceability to the casting date, machining line, and inspection records.

For bulk orders, SANY provides a Certificate of Conformance (CoC) confirming that all 160102130003A100 flanges meet material, dimensional, and flatness specifications. Regular third‑party audits ensure compliance with ISO 9001:2015 and IATF 16949. Trust only genuine SANY flanges for reliable pump mounting.

Field Performance of Genuine SANY Injection Pump Flange

Field data from SANY equipment operating in Australian mines and Canadian oil sands shows that genuine 160102130003A100 flanges last over 20,000 hours without cracking or warping. The ductile iron resists fatigue, and the zinc‑nickel coating remains intact even in salt‑spray environments. Flatness is maintained within 0.05 mm, ensuring leak‑free sealing.

Aftermarket flanges often use gray iron, which is brittle and cracks under vibration. They may have poor flatness, causing O‑ring leaks within 2,000 hours. Genuine SANY flanges eliminate these risks. Fleet owners report 95% fewer pump mounting failures after switching to genuine flanges.

To maximize service life, always replace the flange if the pump is rebuilt or if the engine block mounting surface is damaged. Use a torque wrench for mounting bolts. Following these practices ensures reliable pump mounting and leak‑free operation.