AGG AS4300 Operation And Maintenance Manual

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Page 2 Cautions are provided for the user to operate the engine in a proper way, so as to avoid damage to engine parts and engine performance deterioration. Warnings and cautions in this manual are not complete because AGG Power has no possibility and is not able to foresee all potential risks resulted from the failure to follow the safety cautions and operation instructions.
Page 3: Table Of Contents
Table of Contents 1 Introduction............................1 1.1 To User and Operator......................1 1.2 Notices for Engine Quality Feedback..................1 1.3 Safety Instructions .........................1 1.4 Engine Operation Instructions....................2 1.5 Warning Signs ........................3 2 About the Engine ..........................4 2.1 Engine Outline Diagrams ......................4 2.2 Engine Model Identification ....................8 2.3 Engine Nameplate .........................8 2.4 Specifications and Parameters ....................9 3 Engine Operation..........................
Page 4: Introduction
If there are several problems or a very serious problem, please leave the site as it was and inform us promptly, and then AGG Power will send staff for a joint analysis.
Page 5: Engine Operation Instructions
Contact between electrolyte and skin or eyes must be prevented when replenishing it for the battery, because electrolyte is an acid. In case of skin contact, please flush the contacted part with soap and clean water; in case of eyes contact, flush your eyes for 15 minutes with clean water and seek for medical treatment immediately. Cool the engine first to avoid being hurt by coolant steam when filling coolant.
Page 6: Warning Signs
Do not run the engine at overloaded condition. The belt tension and the other drive devices can only be inspected when the engine is in stop. Malfunction thermostat should be replaced in time but the use of thermostat can not be omitted. Do not remove the lead seals on the the fuel injection pump to make adjustment without permission, or it can cause engine damage or lead to insufficient engine power output.
Page 7: About The Engine
2 About the Engine 2.1 Engine Outline Diagrams 2.1.1 SC10E diesel engine (10L) Intake Side View 1 Oil pan 2 Fuel filter 3 Fuel filter inlet pipe 4 Starting motor 5 Flywheel housing 6 Fuel injection pump 7 Rear Lifting ring 8 Injector fuel return pipe 9 Fuel injection pump fuel inlet pipe 10 Valve cover...
Page 8 Exhaust Side View 1 Oil filter 2 Turbocharger oil drain pipe 3 Oil drain plug 4 Oil cooler 5 Water drain plug 6 Water pump 7 Oil filler cover 8 Turbocharger oil inlet pipe 9 Turbocharger 10 Engine coolant outlet pipe 11 Exhaust manifold and heat shield 12 Air compressor water outlet pipe 13 Oil separator...
Page 9 Front End View 1 Water temperature sensor 2 Water pump pulley 3 Multi wedge belt tensioner 4 Fan pulley 5 Drive belt tensioner 6 Vibration damper 7 Idler pulley 8 Air conditioning compressor pulley 9 Flywheel...
Page 10 1 Flywheel...
Page 11: Engine Model Identification
AGG Power to conduct after-sale technical service. We hope you to put the information and data into the daily record of work of your engine or equipment for later repair and reflection of quality problems. This is helpful to the correct settlement of your problems.
Page 12: Specifications And Parameters
2.4 Specifications and Parameters 2.4.1 AS4300-H3665...
Page 14 2.4.2 AS4300-H3666...
Page 16 2.4.3 AS4300-H3668...
Page 18 2.4.4 AS4300-H3670...
Page 20 2.4.5 AS4300-H3846...
Page 22: Engine Operation
3.2 Lubricating oil AGG-designated special lubricating oil of grade CH-4 and above is strongly recommended for this engine in order to ensure its normal operation and long service life and improve its emissions. If the above lubricating oil is not available, oil of CH-4 grade or above meeting the requirements of American Petroleum Institute (API) can serve as an alternative.
Page 23: Engine Start
3.4 Engine Start Before using the engine, choose proper lubricating oil, fuel and coolant according to local ambient conditions. Besides, the following work should be done before starting: Make a surround inspection of the engine and its starting system, and solve problems in time if any. Check oil pressure and temperature gauges, coolant temperature gauge, warning lights and other instruments for normality.
Page 24 every bearing adequately lubricated and oil pressure stable. Gradually accelerate and load the engine after oil pressure is stable. Check the instruments for operational conditions in engine idle running. Caution: Do not accelerate and load the engine immediately after it is started up. Caution: Do not idle the engine for a long period of time or it can cause problems to the engine.
Page 25: Engine Operation
If the engine hasn’t been used for more than 30 days or its lubricating oil has just been replaced, it is necessary to check the oil level for being within range of the level marks in the dipstick before starting, and prime the fuel system. Refer to Section 4.3 Priming Fuel System for specific operation.
Page 26: Running-In Of A New Or Overhauled Engine
3.6.2 Emergency shutdown Under an emergency or special condition, make an emergency stop to avoid serious engine failure. Manually pulling of the emergency stop handle can achieve an emergency shutdown. 3.7 Running-In of A New or Overhauled Engine When the engine is first put into use or after being overhauled, run the engine for 60 hours (about 2,000 km) in running-in condition and change its oil thereafter before running it in full load condition so as to improve its moving parts working condition and its reliability and service life.
Page 27: Engine Maintenance
4 Engine Maintenance 4.1 Maintenance Schedule The following table gives maintenance period and tasks. Make regular maintenance based on this table. If the engine frequently operates at the ambient temperature below -18°C or above 38°C, or in dusty environment or under a stop-and-go condition, the maintenance period should be shortened properly.
Page 28: Maintenance Record
4.2 Maintenance Record Make a regular maintenance record. You may make your own maintenance log by referring to the format of Maintenance Record below. Maintenance Record Engine Serial No. Engine Model & Order No. Name of User Device Name & Serial No. Kilometers Actual Maintenance...
Page 29: Tasks And Methods Of Engine Maintenance
4.3 Tasks and Methods of Engine Maintenance 4.3.1 Checking engine periphery Check the periphery of the engine each time before starting: Check if the engine is in clean state and free from useless things on it. Check the joints and connections of the fuel system, cooling system and lubricating system for leakage. Check if the fan and its guard are fastened in place.
Page 30 4.3.5 Checking oil level Check the oil level daily before starting the engine or the engine is in stop (at least 10 minutes after being stopped) to provide enough time for oil to flow back to the oil pan. The oil level should be between the upper mark (high oil level) and lower mark (low oil level).
Page 31 4.3.7 Checking electrolyte level Batteries that are not maintenance-free need electrolyte level checking. (1) Check the electrolyte level before starting the engine. Remove the filler cap and check the electrolyte level. It should be at the bottom of the filler port. If necessary, make supplement as per requirement.
Page 32 foreign particles suspend in it and can easily drain with lubricating oil. (2) Clean the installation surface of the oil drain plug on the oil pan. Fit the drain plug with a new gasket and tighten it by 80 N·m. (3) Clean the outside surfaces of the oil filters.
Page 33 4.3.12 Changing oil certifugal filtration spool (if equipped) Oil centrifugal filtration must be replaced with the replacement of oil and oil filter if the engine is equipped with it. (1) Shut down the engine and make sure the oil centrifugal Cover filtration completely stops operation before replacement.
Page 34 (including the primary fuel filter) is changed, there can be air in the fuel system. It is required to prime the fuel system as per following steps: (1) Loosen the bolt of the fuel return pipe. (2) Prime the priming pump until there is no bubble visible in the fuel that outflows from the bolt.
Page 35 (2) Crank the engine to position the first cylinder piston at the top dead center on the compression stroke. Note: When the point indicator points at the mark 0 in the vibration damper and the cut in the camshaft gear faces up, the piston of No.
Page 36 4.3.19 Checking belt tensioner (1) Rotate the belt tensioner clockwise, and remove the drive belt. Turn the tensioner pulley to check it for seizure or radial/axial movement, by which to determine if there is scratch or wear on the bearing surface of the tensioner pulley.
Page 37 Air inlet unloader valve Carefully check unloader valve for carbon deposit. Clean and remove deposit if it is serious. Check the air compressor head, inlet and outlet for any problems and replace them or relevant parts if necessary. 4.3.24 Changing coolant and cleaning cooling system In order to ensure the engine coolant to be good in cooling and anticorrosion, changing of coolant and cleaning of cooling system are required every 80,000 km, 2,000 hours or 2 years, whichever comes first.
Page 38 (d) Start the engine and keep it running for 5 minutes after the water temperature goes up to above 80 , then stop the engine and completely drain the clean water in the cooling system. Caution: If the discharged water is still dirty, clean the cooling system again according to the above steps until discharged water becomes clean.
Page 39 4.3.26 Cleaning air filter element (non-paper element) Remove the air filter cover and the element. Dip the element in warm neutral cleaning liquid to remove oily dirt on it. Do not use brush for cleaning. Dry the element after cleaning. Flushing afterward with clean water is necessary when non-neutral claneing liquid is used.
Page 40: Troubleshooting Guidelines
5 Troubleshooting Guidelines Some simple typical diesel engine fault modes, possible causes and troubleshooting steps are listed in the table below. If any one of modes occurs in engine operation, it is required to eliminate it by taking appropriate measures. Otherwise, it would lead to severe engine failure.
Page 41 Fault mode 3 Engine is difficult to start or will not start Possible cause Correction Refer to the operating instruction manual of the Improper starting method vehicle or the equipment for proper starting method The time for engine start up is 2-3 seconds It is normal and needs no adjustment The drive system is engaged Disengage the drive system...
Page 42 Fault mode 5 Liable misfire or unsteady speed Possible cause Correction Fuel level in the fuel tank too low Add fuel Check for air in the system. Tighten or replace the Air in fuel system fuel joints, fuel pipes if necessary and then prime the system Check the fuel tank for fuel level, check the pipe between the tank and the fuel transfer pump for...
Page 43 Fault mode 8 Engine power output low Possible cause Correction Inquire the driver or operator Obtain all the information related to the problem Overloaded operation Reduce the load to allowed range The engine runs on the plateau beyond the Run the engine on the specified plateau. Engine specification power decreases with increase of altitude The drive system has been changed and cannot...
Page 44 Fault mode 10 Unexpected engine halt or misfire in deceleration Possible cause Correction Causes related to the protective system of the Contact the manufacturer of the vehicle or vehicle or equipment equipment Check for air in the system. Tighten or replace the Air in the fuel system fuel joints, fuel pipes if necessary and then prime the system...
Page 45 Fault mode 14 Rough running at idle speed Possible cause Correction Engine temperature is too low Warm up the engine The load at idle speed is too heavy (more than 50 Reduce the load at idle speed horsepower) Leakage of the intercooler or its pipeline Check intercooler and its pipeline for leaks Leakage of the intake manifold or pipeline Check the intake manifold or pipeline for leaks...
Page 46 Fault mode 17 Excessive noise Possible cause Correction Noise from drive belt due to poor tension or Check the belt drive system and ensure all pulleys heavy load running Check the intake and exhaust systems for leakage. Leakage of intake system and exhaust system Tighten the loose components and replace the related parts if necessary Check the blades of compressor or turbine for their...
Page 47 Fault mode 21 Fuel consumption too much Possible cause Correction Check driver’s operation for gear shift, deceleration Something related to driving technique and idle speed Display error of the odometer Adjust or replace the odometer Check the transmission gears and make sure that The drive system cannot match the engine the components of the engine and drive system are correct...
Page 48 Fault mode 23 Coolant temperature above normal—sudden overheat Possible cause Correction Check coolant level and engine external for Coolant level is too low leakage, eliminating the leakage and adding the coolant to be within the specified range Coolant system hose(s) is collapsed and there is Check the hose(s) and replace it if necessary leakage The drive belt is broken...
Page 49 Fault mode 27 Oil pressure too high Possible cause Correction The operating temperature of the engine is too Refer to the fault mode “Coolant temperature below low and the oil viscosity is high normal” Fault of the oil pressure meter or pressure sensor Check the pressure meter and sensor, and make replacement when necessary Use the lubricating oil specified in this manual and...
Page 50: Engine Storage
6 Engine Storage 6.1 Short time storage If the engine is to be out of service for a period of time (1 to 3 months), measures of cleaning and necessary oil seal should be taken for rust protection. 6.1.1 Before storage (1) Clean the engine surface and check for any dirt, or oil stain or water stain and rust.
Page 51 (1) On last engine operation, drain the lubricating oil in the engine and oil filter after the engine has stopped and cooled down to warm state. It is not necessary to drain coolant because it is anti-rust. Add qualified anti-rust oil (dewatered CF 15W-40 oil) into the engine, start the engine to idle for 1-1.5 minutes and stop it, then drain the anti-rust oil.

This manual is also suitable for:

As4300-h3665 As4300-h3666 As4300-h3668 As4300-h3670 As4300-h3846