AGG AS4300 User manual

Operation and
Maintenance
Manual
Diesel Engine
AS4300
AGG201806
June 2018

Caution
Be sure to read this instruction manual carefully and strictly observe the safety
and operation instructions herein, especially the warnings and cautions, so as to
reduce the possibilities of personnel injury, property loss, engine performance
deterioration, premature wear or damage.
Warnings in this manual must be observed strictly. Failure to do so can cause
burns, amputation, mutilation, asphyxiation and other personal injury or death.
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.
Repair, Technical Consultation, Complaint and
Suggestion
For engine repair, technical consultation, complaints or suggestions, please
contact AGG Power’s after-sale service center: [email protected].
Please provide the following information for product repair:
The model of diesel engine
The order number of diesel engine
The serial number of diesel engine
The date of equipment procurement
The detailed description of fault
The address and phone number of contact person

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.............................................................................................................................19
3.1 Fuel ........................................................................................................................................19
3.2 Lubricating oil........................................................................................................................19
3.3 Coolant...................................................................................................................................19
3.4 Engine Start ..........................................................................................................................20
3.5 Engine Operation.................................................................................................................22
3.6 Engine Shutdown.................................................................................................................22
3.7 Running-In of A New or Overhauled Engine....................................................................23
4 Engine Maintenance.......................................................................................................................24
4.1 Maintenance Schedule........................................................................................................24
4.2 Maintenance Record............................................................................................................25
4.3 Tasks and Methods of Engine Maintenance....................................................................26
5 Troubleshooting Guidelines ...........................................................................................................37
6 Engine Storage ................................................................................................................................47
6.1 Short time storage................................................................................................................47
6.2 Long time storage ................................................................................................................47

1
1 Introduction
1.1 To User and Operator
Thank you for purchasing a product of AGG Power!
The AS4300 series diesel engine, available in two displacements of 10L and 12L, is a large-power four-valve
diesel engine with four or six cylinders that is newly developed by AGG Power. Featuring strong power and
low fuel consumption and with the emissions conforming to relevant national regulations, the AS4300 series
diesel engine is a perfect power for the medium- and high-end heavy-duty vehicles and industrial equipment.
This manual mainly covers technical specifications, operation and maintenance instruction, with an aim to familiarize
you with the engine, as well as the proper operation and maintenance thereof. Before using the engine, read carefully
the relevant contents and requirements in this manual. Due to the continuous improvement of performance and
structure of the engine, the technical specifications and illustrations of the engine in this manual may be slightly
different from those of he engine you have, please note that we will provide the supplement and perfection in the later
editions without notice. In case of any question during your engine operation and maintenance, please never hesitate
to contact AGG Power’s after-sale service center [email protected] for technical advice or guidance.
AGG Power has adopted the latest technology and high-quality parts for the engine. The genuine AGG Power
service parts are recommended to be used for repair and maintenance. Please contact AGG Power’s
after-sale service center [email protected] for service parts.
Since this manual ensures proper engine operation and maintenance, it should be given to the new owner when the
engine is traded or sold.
1.2 Notices for Engine Quality Feedback
To better our service, please provide following information when you make feedback about quality issue(s), whereby,
we can understand and analyze the quality issue(s) and the root cause(s) thereof, and make the improvement in time:
1) When and where fault occurred;
2) Engine serial number, model, order number, delivery date and the detailed address of consignee;
3) Service conditions, cumulative operation time (in hours or kilometers), operating conditions (power, speed) and the
grade of fuel and lubricating oil that were used;
4) The characteristics of driven equipment (model, power consumption and structural feature, etc.)
5) The description of faults;
6˅Parts or components claimed for compensation or repair should be mailed or sent in person to AGG Power
headquarter with the damage process record or description for facilitating analysis. 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. Quality issues should be settled based on the relevant provisions in the quality warranty manual.
1.3 Safety Instructions
ƔDo not wear a loose garment or any jewelry when working around the engine or its driven equipment. If necessary,
wear safety goggles, work clothes, safety helmet or other protective items.
ƔAll the exposed rotating parts should be provided with guards with firm installation to prevent personal injury.
ƔThe workroom of the engine should be well ventilated with waste gas exhausted outside.
ƔNo flammable liquid is allowed to be around the engine.
ƔTake all tools, wires, other odds and ends away from the engine prior to starting.
ƔMake sure to shutdown the engine before any adjustment is performed to it and its driven equipment.
ƔSmoking is not allowed during fuel filling, otherwise, fuel steam can cause fire easily.
ƔSmoking is also not allowed when checking electrolyte level because electrolyte will release flammable gas.

2
ƔContact 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.
ƔCool the engine first to avoid being hurt by coolant steam when filling coolant. Open the pressure cap only when the
coolant is lower than 50ć, and then slowly loosen the cap to release the pressure of coolant.
ƔWipe up lubricating oil, fuel, Coolant or other liquids overflowed. Put oily rags into a fire-protection container, but not
leave it on the engine.
ƔBefore starting the engine after being repaired, make sure to be ready to cut air supply. In case of any abnormal, cut
air supply to stop the engine immediately.
ƔDo not rotate the engine with the fan, otherwise severe personal injury or damage to fan blades can be caused.
ƔDo not touch by hand the intake and exhaust system components such as the exhaust manifold, turbocharger,
intercooler air inlet pipe, expand tank because they are in high temperature when the engine is in operation.
ƔRelease the pressure in the air system, lubricating system, cooling system or fuel system prior to dismantling or
loosening any pipelines, permanent joints, connectors or relevant parts of these systems. Do not check leakage with
hand, otherwise high pressure and high temperature fuel, lubricating oil and coolant can cause personal injury.
ƔIf the engine will not be used for a long time or is under repair, separate it from the battery to prevent an unexpected
start-up. Meanwhile, place a sign STOP in the operation room or on the controller.
ƔUsed lubricating oil may contain carcinogenic substance which can result in reproductive toxicity, therefore,
inhalation of or longtime exposure to oil steam should be avoided. Waste oil should be disposed in proper, safe and
reliable manner.
ƔTo prevent choke or cold injury, removal of air-conditioning refrigerant (Freon) pipeline should be conducted in
well ventilated environment with protective clothing worn. For environment protection, the refrigerating system
should be emptied or filled using dedicated equipment so as to prevent diffusion of Freon into atmosphere.
Refrigerant should be recovered and recycled.
1.4 Engine Operation Instructions
ƔRead this manual carefully, and be in strict accordance with operation instructions and maintenance procedure
specified in this manual.
ƔConduct daily and 4-levele maintenance as specified in this manual, and keep the records of scheduled
maintenance.
ƔUse the proper fuel, lubricating oil and coolant specified in this manual.
ƔWhen filling lubricating oil, it is not allowed to use the mixture of different-graded oil.
ƔThe coolant specified in this manual should be used for the engine cooling system at any kind of climate.
Ɣ60 hours’ running-in must be conducted for a new or overhauled engine. Please refer to Section 3.7 for the
running-in requirements.
ƔDo not start the engine without air filter, otherwise, early engine wear will be caused.
ƔPreparations should be well done before starting the engine. Be sure to remember that the engine must be started
without load.
ƔCheck if coolant, lubricating oil and fuel are enough before starting the engine. It is not allowed to start the engine
with lack of diesel fuel in the fuel tank. The fuel tank should be replenished; or it will cause damage to the high
pressure fuel pump.
ƔObserve the engine operation and all the instrument readings. In case of critical situation, an emergency stop should
be performed to prevent the seizure of moving parts caused by low oil pressure or overheating due to lack of coolant.
ƔDo not run the engine at high load and high speed when the coolant temperature is blow 60ć.

3
ƔDo not run the engine at overloaded condition.
ƔThe belt tension and the other drive devices can only be inspected when the engine is in stop.
ƔMalfunction thermostat should be replaced in time but the use of thermostat can not be omitted.
ƔDo 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. If necessary, send the relevant components to a
professional service provider for repair or/and adjustment.
ƔDo not change the application and scope of the engine without permission, or it can cause damage to the engine
or/and equipment.
1.5 Warning Signs
There are some warning sings on the engine. It is required to observe them, or it can cuase harms to man and the
engine.
Warning
When driving downhill,
engine speed should not
be higher an 1,900 r/min
Warning
1. Do not hoist the
engine in trangle way.
2. Keep the hoiting
smoothly.
Engine Engine

4
2 About the Engine
2.1 Engine Outline Diagrams
2.1.1 SC10E diesel engine (10L)
Intake Side View
1Oilpan 2Fuelfilter 3Fuelfilterinletpipe
4Startingmotor 5Flywheelhousing 6Fuelinjectionpump
7 Rear Lifting ring 8 Injector fuel return pipe 9 Fuel injection pump fuel inlet pipe
10 Valve cover 11 High pressure fuel pipe 12 Solenoid fuel inlet pipe
13 Fuel shut-off solenoid 14 Solenoid fuel outlet pipe 15 Flame heating plug
16Frontlifting 17Intakemanifold 18Oildipstick
19 Multi-V belt 20 Air conditioning compressor 21 Drive belt
22Alternator

5
Exhaust Side View
1Oilfilter 2Turbochargeroildrainpipe
3Oildrainplug 4Oilcooler
5Waterdrainplug 6Waterpump
7 Oil filler cover 8 Turbocharger oil inlet pipe
9Turbocharger 10Enginecoolantoutletpipe
11 Exhaust manifold and heat shield 12 Air compressor water outlet pipe
13Oilseparator 14Crankcasefiltrationgasoutletpipe
15 Crankcase filtration oil drain pipe 16 Air compressor

6
1Watertemperaturesensor 2Waterpumppulley
3 Multi wedge belt tensioner 4 Fan pulley
5Drivebelttensioner 6Vibrationdamper
7 Idler pulley 8 Air conditioning compressor pulley
9 Flywheel
Front End View

7
1 Flywheel

8
2.2 Engine Model Identification
The model name represents the meanings as follows:
AS 4300
For example: AS4300 stands for AGG Power AS series diesel engine with displacement of 4300 ml.
2.3 Engine Nameplate
The diesel engine nameplate indicates the main technical data and information: engine model, order number, serial
number, date of manufacture, rated power and rated speed, which are the major basis for you to purchase service
parts and for 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. The nameplate locates at the side of the valve cover (intake side).
Protect it from being damaged.
Note: Do not change the nameplate without our permission!
4300 Displacement ml
AGG Power AS series diesel engine

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2.4 Specifications and Parameters
2.4.1 AS4300-H3665
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17