Original SANY Hexagon Screw Plug 160102120007A004 Construction Machinery Parts

The genuine SANY parts reference 160102120007A004 is the Hexagon Screw Plug, a high‑quality threaded plug used to seal ports in SANY hydraulic systems, engine blocks, and transmission housings. The 160102120007A004 hexagon screw plug features a precision‑cut metric thread and a pre‑applied anaerobic sealant that prevents oil, fuel, or coolant leaks under high pressure and vibration.

Manufactured from zinc‑nickel plated carbon steel, this plug withstands pressures up to 350 bar and temperatures from -40°C to +150°C. Each 160102120007A004 unit is 100% inspected for thread form, sealant coverage, and pressure integrity, ensuring reliable sealing in SRT dump trucks, SY excavators, SW wheel loaders, and motor graders.

Hexagon Screw Plug

Винтовая пробка с шестигранной головкой

Tapón de cabeza hexagonal

Hexagon Screw Plug

Винтовая пробка с шестигранной головкой

Tapón de cabeza hexagonal

Hexagon Screw Plug

Винтовая пробка с шестигранной головкой

Tapón de cabeza hexagonal

Material and Design of Hexagon Screw Plug 160102120007A004

The hexagon screw plug 160102120007A004 is machined from carbon steel (C35E) and case‑hardened to a surface hardness of 50-55 HRC. The thread is metric parallel M12 x 1.75 with tolerance 6g, rolled for fatigue resistance. The plug body has an external hexagon drive (17 mm across flats) for installation and removal using standard sockets. A lead‑in chamfer prevents cross‑threading.

A microencapsulated anaerobic sealant (dimethacrylate ester) is pre‑applied to the middle three threads. When the plug is tightened, the capsules rupture and the sealant cures in the absence of air (20‑30 minutes at room temperature). The cured sealant resists engine oil, diesel, coolant, brake fluid, and hydraulic oil up to 150°C. The sealant also lubricates threads for consistent torque.

The external surface is zinc‑nickel plated (8-12 µm) with a black trivalent passivation, providing 500 hours of salt spray resistance to red rust (ASTM B117). The plug has a flat sealing face that mates with a copper washer or an O‑ring groove depending on the application. The overall length is 18 mm (for M12 x 1.75 – 12 mm thread length).

All 160102120007A004 plugs are 100% inspected: thread go/no‑go, hex size, sealant coverage (minimum 3 threads). A sample from each batch is torqued to 50 Nm in a test fixture and subjected to 350 bar hydraulic oil pressure for 2 minutes with zero leakage. A laser‑etched batch code on the hex face provides full traceability.

Critical Sealing Applications of Plug 160102120007A004

The hexagon screw plug 160102120007A004 is used to seal unused ports on SANY engine blocks (oil gallery test ports), hydraulic valve manifolds (pressure test points), and transmission cases (level check ports). On SRT dump trucks, it seals the brake accumulator test port and the hydraulic tank drain plug bore. On SY excavators, it plugs unused ports on the main control valve and swivel joint.

In SANY diesel engines (D07/D09/D12), 160102120007A004 seals the fuel return line port on the injection pump and the water drain on the fuel filter head. The pre‑applied sealant eliminates the need for PTFE tape or liquid pipe dope. The plug is designed for one‑time use; if removed, the sealant is disrupted and cannot reseal. Always replace with a new plug.

Do not substitute with a standard set screw or a plug without sealant – leakage is almost certain. The plug’s external hex head allows installation in confined spaces using a standard socket wrench. For high‑vibration applications, the sealant also acts as a threadlocker, preventing loosening.

Compatible SANY Models & Interchange Information

The hexagon screw plug 160102120007A004 is used across SANY’s heavy equipment line: SRT45, SRT55, SRT95, SRT115 dump trucks; SY215 to SY500H excavators; SW305, SW405, SW465 wheel loaders; SMG200/220 graders; and STC crawler cranes. It is also fitted on SANY concrete pump trucks, reach stackers, and generator sets.

The specific thread is M12 x 1.75 (metric coarse). Always verify the original plug thread pitch. For M10 or M14 ports, other part numbers are required. When ordering, specify 160102120007A004 to receive the correct metric coarse thread, zinc‑nickel finish, and pre‑applied anaerobic sealant.

For fleet maintenance, stock genuine plugs. Aftermarket plugs often use a dry thread (no sealant) or a substandard acrylic coating that fails in hot oil. Genuine SANY plugs guarantee the correct sealant chemistry, cure time, and pressure rating for leak‑proof sealing in all operating conditions.

Technical Specifications – Hexagon Screw Plug 160102120007A004

Proper Installation of Hexagon Screw Plug 160102120007A004

Before installing the plug 160102120007A004, clean the port threads with a solvent and blow dry. Do not use a tap to chase threads unless they are damaged – oversize threads will not compress the sealant properly. The plug comes with pre‑applied sealant; do not add PTFE tape, pipe dope, or threadlocker. Any additional sealant will interfere with the anaerobic cure.

Thread the plug into the port by hand until it seats. Then use a 17 mm hex socket and a torque wrench to tighten to 50 Nm. Do not exceed 60 Nm. Over‑torquing can strip the hex head or damage the threads. The sealant will begin to cure within 20 minutes. Pressure can be applied immediately, but full chemical resistance (especially to diesel) is achieved after 24 hours.

If the plug is removed for any reason, discard it. The sealant capsules are crushed and the anaerobic residue will not reseal. Install a new 160102120007A004 plug. Never reuse a plug that has been tightened before. Store new plugs in a cool, dry place (below 30°C) and use within 2 years of manufacture.

Symptoms of a Damaged or Incorrect Plug 160102120007A004

A leaking 160102120007A004 plug shows fluid seepage around the hex head or down the side of the component. On an engine block, you may see oil or coolant weeping from a test port. On a hydraulic manifold, you will see hydraulic oil film or drips. A small leak can rapidly worsen due to pressure cycling and temperature changes.

If the hex head strips, the plug may be impossible to remove. This is often caused by using a worn socket or over‑torquing. If the plug was cross‑threaded, it may leak immediately and also damage the port threads. Always start the plug by hand to avoid cross‑threading. If sealant is missing (dry threads), the plug will not seal.

During maintenance, inspect the plug for rust (zinc‑nickel coating should remain intact) and for any sign of sealant degradation (cracking or missing). If the plug shows any damage or has been in service for more than 5 years, replace it preventively. Use only genuine 160102120007A004 plugs for replacement.

Quality Assurance & Full Traceability for 160102120007A004

Every hexagon screw plug 160102120007A004 is manufactured in an IATF 16949 certified facility. The process includes cold heading, thread rolling, case hardening, zinc‑nickel plating, and automated sealant application. In‑process inspections verify thread quality (laser), hex head dimensions (vision), and sealant coverage (weight gain).

A sample from each production batch is torqued to 50 Nm into a test fixture and then pressurized to 350 bar with hydraulic oil at 120°C for 2 hours. Zero leakage is permitted. The sealant is also tested for cure time (no more than 30 min) and oil resistance (no degradation after 1000 hours in hot oil). A laser‑etched batch code on the hex head provides full traceability to material lot, heat treatment batch, and sealant lot.

For bulk orders, SANY provides a Certificate of Conformance (CoC) confirming that all 160102120007A004 plugs meet dimensional, material, coating, and sealing specifications. Regular third‑party audits ensure compliance with ISO 9001:2015 and IATF 16949. Trust only genuine SANY plugs for leak‑free high‑pressure sealing.

Field Performance of Genuine SANY Hexagon Screw Plug

Field data from SANY equipment operating in Australian mines and Indonesian palm oil plantations shows that genuine 160102120007A004 plugs maintain a leak‑free seal for over 10,000 operating hours or 5 years, whichever comes first. The anaerobic sealant remains flexible and does not crack or dissolve in hot engine oil or hydraulic fluid.

Aftermarket plugs often fail within 1,000 hours due to sealant that hardens and cracks (cheap cyanoacrylate) or no sealant at all, requiring messy liquid thread sealant. Genuine SANY plugs also have superior corrosion resistance; the zinc‑nickel coating withstands road salt and high humidity. Fleet owners report 90% fewer port leaks after switching to genuine 160102120007A004 plugs.

To maximize service life, always replace the plug whenever the port is opened. Use a torque wrench set to 50 Nm. Store plugs in a sealed bag away from moisture. Following these practices ensures long‑term, leak‑free operation of critical fluid systems.