Original SANY Fuel Injector 160102130004A019 Construction Machinery Parts

The genuine SANY parts reference 160102130004A019 is the Fuel Injector, a precision‑engineered high‑pressure nozzle that delivers atomized diesel fuel directly into the combustion chamber of SANY heavy‑duty diesel engines. The 160102130004A019 fuel injector features a seven‑hole nozzle, a hardened needle valve, and a solenoid actuator, providing precise injection timing and fuel metering for optimal power and emissions control.

Manufactured from hardened alloy steel with a corrosion‑resistant coating, this injector withstands injection pressures up to 2000 bar and combustion temperatures exceeding 500°C. Each 160102130004A019 unit is 100% flow‑tested and spray‑pattern inspected, guaranteeing reliable fuel delivery in SRT dump trucks, SY excavators, SW wheel loaders, and motor graders.

Fuel Injector

Топливная форсунка

Inyector de combustible

Fuel Injector

Топливная форсунка

Inyector de combustible

Fuel Injector

Топливная форсунка

Inyector de combustible

Material and Design of Fuel Injector 160102130004A019

The fuel injector 160102130004A019 is a solenoid‑operated, common‑rail injector type. The body is machined from hardened alloy steel (20MnCr5) and case‑hardened to 58-62 HRC. The needle valve is made from tool steel with a lapped sealing seat (Ra ≤ 0.05 µm). The nozzle has seven precision laser‑drilled holes (diameter 0.12 mm) arranged in a conical pattern to ensure even fuel distribution in the combustion chamber.

The solenoid coil is encapsulated in high‑temperature epoxy and rated for continuous operation at 130°C (peak 150°C). The injector includes a hydraulic servo system that multiplies the solenoid force to lift the needle valve. The maximum injection pressure is 2000 bar, and the dynamic flow range is from 2 mm³/stroke at idle to 80 mm³/stroke at full load. The injector has a return fuel leak rate of less than 5% of total flow.

The external surfaces are zinc‑nickel plated (8-12 µm) with black trivalent passivation, providing 500 hours of salt spray resistance. The injector has a two‑pin electrical connector (Deutsch DT04‑2P compatible) with a sealed boot. The overall length is 125 mm, and the outside diameter of the nozzle body is 12 mm. A copper sealing washer (supplied separately) is required for installation.

All 160102130004A019 injectors are 100% tested on a common‑rail test bench. Static flow (at 1000 bar) is measured for each injector and must be within ±3% of nominal. The spray pattern is visually inspected using a high‑speed camera. Solenoid resistance is checked (0.5-1.5 Ω). A laser‑etched batch code on the injector body provides full traceability to the assembly date, test data, and component lots.

Function of Fuel Injector 160102130004A019 in Engine Performance

The fuel injector 160102130004A019 is responsible for delivering precisely metered diesel fuel into the engine cylinder at the exact moment required for optimal combustion. The ECU sends an electrical pulse to the solenoid, which opens the needle valve, allowing high‑pressure fuel to spray through the nozzle holes. The atomized fuel mixes with compressed air, ignites, and produces power.

A worn or clogged injector will cause rough idle, black smoke, loss of power, increased fuel consumption, and misfiring. Leaking injectors (needle valve not seating) can dilute the engine oil with diesel, causing serious damage. The injector must be handled with extreme care – the nozzle holes are easily damaged by debris. Always use new copper sealing washers when replacing injectors.

On SANY D07/D09/D12 engines, these injectors are installed in the cylinder head, accessed after removing the valve cover. They are held in place by injector clamps (60352132). The injector wiring harness is protected by a heat shield. Never swap injectors between cylinders without recalibrating the ECU (injector individual codes).

Compatible SANY Models & Interchange Information

The fuel injector 160102130004A019 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 injector has a M16 x 1.5 threaded body and uses a copper sealing washer (size 10 mm x 1.5 mm). The electrical connector is a 2‑pin Deutsch DT04‑2P. The injector code (IQA code) is printed on the body and must be programmed into the ECU after replacement. When ordering, specify 160102130004A019 to receive the correct flow rate, nozzle configuration, and solenoid resistance.

For fleet maintenance, stock genuine 160102130004A019 injectors. Aftermarket injectors often have incorrect hole sizes or poor spray patterns, leading to incomplete combustion, carbon buildup, and piston damage. Genuine SANY injectors guarantee precise flow matching and reliable operation.

Technical Specifications – Fuel Injector 160102130004A019

Proper Installation of Fuel Injector 160102130004A019

Before installing the injector 160102130004A019, clean the injector bore in the cylinder head. Remove carbon deposits using a special reamer. Install a new copper sealing washer on the nozzle tip. Lubricate the injector body with clean engine oil. Insert the injector into the bore by hand – do not force it. Rotate gently until it seats.

Install the injector clamp (SANY 60352132) and torque the clamp bolts to 25 Nm in a cross pattern. Connect the high‑pressure fuel line and tighten to 35 Nm. Plug in the electrical connector until it clicks. After installation, prime the fuel system and check for leaks. The injector IQA code must be programmed into the ECU using a diagnostic tool.

Never reuse a copper sealing washer. Always use a new washer. Do not use impact tools on the injector. Store new injectors in sealed bags to prevent dirt ingress. If an injector is dropped, do not install it – the nozzle may be damaged. Use only genuine SANY injectors for guaranteed performance.

Symptoms of a Failed Fuel Injector 160102130004A019

A failed 160102130004A019 injector will cause rough idle, misfiring, white or black smoke from the exhaust, and increased fuel consumption. The engine may run unevenly, especially at low speed. A stuck‑open injector will cause a knocking sound (diesel knock) and may fill a cylinder with fuel, leading to hydro‑lock and severe engine damage.

A clogged nozzle will cause a noticeable loss of power, high exhaust gas temperature, and soot buildup on the injector tip. Leakage past the needle seat will cause diesel fuel to enter the engine oil, detectable by a sharp smell on the dipstick and a rising oil level. A faulty solenoid will cause a cylinder to stop firing completely, shown by a DTC and a noticeable power loss.

During preventive maintenance, injectors should be tested every 4,000 hours or if any symptoms appear. Replace the injector if the flow deviation exceeds ±5% or if the spray pattern is irregular. Use only genuine SANY injectors for replacement.

Quality Assurance & Full Traceability for 160102130004A019

Every fuel injector 160102130004A019 is manufactured in an IATF 16949 certified facility. The body and needle are machined on high‑precision CNC lathes. The nozzle holes are drilled by femtosecond laser, then examined with a vision system to ensure roundness and burr‑free edges. Each injector is flow‑tested at four pressure points, and the results are stored in a database.

A sample from each batch is endurance‑tested for 1000 hours at full load with no degradation in flow or opening time. Salt spray testing (500 hours) verifies coating integrity. The solenoid is tested for insulation resistance and pull‑in voltage. A laser‑etched batch code on the injector body provides traceability to the machining date, assembly line, and test data.

For bulk orders, SANY provides a Certificate of Conformance (CoC) confirming that all 160102130004A019 injectors meet flow, spray, and electrical specifications. Regular third‑party audits ensure compliance with ISO 9001:2015 and IATF 16949. Trust only genuine SANY injectors for optimal engine performance.

Field Performance of Genuine SANY Fuel Injector

Field data from SANY equipment operating in Australian mines and Brazilian sugar cane fields shows that genuine 160102130004A019 injectors last over 12,000 hours before requiring replacement. The hardened needle and seat resist wear, and the seven‑hole nozzle maintains a consistent spray pattern. Fuel consumption remains within 3% of new injector values throughout the service life.

Aftermarket injectors often have shorter service life (4,000‑6,000 hours) due to poor metallurgy or inaccurate hole sizing. They may also leak at the needle seat, diluting engine oil and causing bearing failure. Genuine SANY injectors eliminate these risks. Fleet owners report 95% fewer injector‑related breakdowns after switching to genuine injectors.

To maximize service life, use clean diesel fuel and change fuel filters regularly (500 hours). Replace injectors as a set (all six) when one fails. Use a torque wrench for installation. Following these practices ensures reliable fuel injection and optimal engine performance.