## MACK AC-300, AC-400 Emissions Gas Recirculation (EGR) All Seasons Engine Technology (ASET) Engine Workshop Service Manual

### **Introduction**

The MACK AC-300 and AC-400 engines are renowned for their exceptional performance, reliability, and efficiency. These engines are specifically engineered to meet the demands of heavy-duty applications, offering superior power and torque for a wide range of vehicles. This comprehensive workshop service manual provides detailed instructions and technical information to facilitate the maintenance, repair, and troubleshooting of these advanced engines.

### **Engine Overview**

The MACK AC-300 and AC-400 engines are inline-six, diesel-powered engines with a displacement of 11.0 liters and 12.8 liters, respectively. They feature a robust cast-iron block and cylinder head, ensuring exceptional durability and longevity. The engines are equipped with a high-pressure common-rail fuel injection system, which delivers precise fuel delivery for enhanced performance and fuel efficiency.

### **Emissions Gas Recirculation (EGR) System**

The EGR system plays a crucial role in reducing nitrogen oxide (NOx) emissions by recirculating a portion of the exhaust gases back into the combustion chamber. This process effectively lowers combustion temperatures, reducing the formation of NOx. The AC-300 and AC-400 engines utilize a cooled EGR system, which involves passing the exhaust gases through a heat exchanger to cool them before recirculation. This cooling process enhances the NOx reduction efficiency and optimizes engine performance.

### **All Seasons Engine Technology (ASET)**

The ASET system is a unique feature of the MACK AC-300 and AC-400 engines. It incorporates an air-to-air aftercooler, which effectively cools the compressed intake air, resulting in increased air density and improved engine efficiency. This advanced system provides optimal performance in all operating conditions, including extreme heat or cold.

### **Technical Features**

- Inline-six, diesel-powered engines
- Displacement: 11.0 liters (AC-300) and 12.8 liters (AC-400)
- Cast-iron block and cylinder head
- High-pressure common-rail fuel injection system
- Cooled Emissions Gas Recirculation (EGR) system
- All Seasons Engine Technology (ASET) with air-to-air aftercooler
- Electronic engine controls and diagnostics
- Superior power and torque

### **Benefits**

- Enhanced performance and fuel efficiency
- Reduced nitrogen oxide (NOx) emissions
- Optimal operation in all operating conditions
- Extended engine life and reliability
- Ease of maintenance and repair

MACK AC-300 AC-400 EGR ASET DIESEL ENGINE WORKSHOP SERVICE REPAIR MANUAL




APPLICABLE ENGINE MODEL:
ASET AC-310/330 (CEGR) MAXICRUISE
ASET AC-330/350 (CEGR) MAXICRUISE
ASET AC-355/380 (CEGR) MAXICRUISE
ASET AC-380/410 (CEGR) MAXICRUISE
ASET AC-350 (CEGR) ECONODYNE
ASET AC-400 (CEGR) ECONODYNE
ASET AC-427 (CEGR) ECONODYNE
ASET AC-460(E) (CEGR) ECONODYNE
ASET AC-460(P) (CEGR) ECONODYNE


CONTENTS:
INTRODUCTION
VISUAL IDENTIFICATION
DESCRIPTION AND OPERATION
COMPONENT LOCATOR
TROUBLESHOOTING
ENGINE SYMPTOM DIAGNOSIS
ENGINE BRAKE TESTS
MAINTENANCE
FUEL FILTER ELEMENT REPLACEMENT
COOLANT CONDITIONER ELEMENT REPLACEMENT
OIL COALESCING AIR FILTER REPLACEMENT
DRIVE BELT REPLACEMENT AND TENSIONING
ENGINE REMOVAL
ENGINE DISASSEMBLY
CYLINDER BLOCK RECONDITIONING
CRANKSHAFT & FLYWHEEL BENCH
AUXILIARY SHAFT & CAMSHAFT BENCH
CONNECTING ROD AND PISTON BENCH
CYLINDER HEAD OVERHAUL
VALVE ROCKER ARM SHAFT BENCH
LUBRICATION SYSTEM
COOLING SYSTEM
FUEL SYSTEM
VTG SYSTEM
ENGINE REASSEMBLY
ENGINE INSTALLATION
IN-CHASSIS PART/COMPONENT
ELECTRONIC UNIT PUMP REPLACEMENT
EXHAUST VALVE YOKE
EECU AND SENSOR SERVICE
EGR SYSTEM SERVICE
VTG TURBOCHARGER SERVICE
ENGINE SETUP AND ADJUSTMENTS
ENGINE SPEED AND POSITION SENSORS
REBUILT ENGINE RUN-IN PROCEDURES
ENGINE MECHANICAL SPECIFICATIONS
SPECIAL TOOLS & EQUIPMENT
FASTENER IDENTIFICATION
TORQUE WRENCH USE
TURBOCHARGER FAILURE AND ACTIONS
SCHEMATIC & ROUTING DIAGRAMS



THIS MANUAL IS COMPATIBLE WITH THE FOLLOWING COMPUTER OPERATING SYSTEMS:

# ALL WINDOWS VERSION
# ALL MAC VERSION

# YOU NEED THE ADOBE ACROBAT READER TO VIEW THE DOCUMENT AS THE MANUAL IS PDF FORMAT. IF YOUR COMPUTER DON'T HAVE THIS APPLICATION YOU CAN DOWNLOAD AND INSTALL IT FREE FROM ADOBE ACROBAT WEBSITE

# AS THIS MANUAL IS COMING TO YOU IN ZIP FORMAT, YOU NEED TO EXTRACT THE FILE BEFORE USE BY USING WINZIP OR WINRAR SOFTWARE. IF YOUR COMPUTER DON'T HAVE THIS APPLICATION YOU CAN DOWNLOAD AND INSTALL IT FREE FROM WINZIP WEBSITE


THIS IS A VERY COMPREHENSIVE AND INTUITIVE ELECTRONIC PDF FORMAT WORKSHOP MANUAL WHICH HAS DETAILED ILLUSTRATIONS AS WELL AS STEP BY STEP INSTRUCTIONS WITH PICTURES & DIAGRAMS. ALL PAGES ARE PRINTABLE, SO RUN OFF WHAT YOU NEED AND TAKE IT WITH YOU INTO THE GARAGE OR WORKSHOP. THIS MANUAL ARE YOUR NUMBER ONE SOURCE FOR REPAIR AND SERVICE INFORMATION. THEY ARE SPECIFICALLY WRITTEN FOR THE DO-IT-YOURSELF AS WELL AS THE EXPERIENCED MECHANIC. USING THIS REPAIR MANUAL IS AN INEXPENSIVE WAY TO KEEP YOUR MACHINE/VEHICLE WORKING PROPERLY. EACH MANUAL PROVIDES STEP-BY-STEP INSTRUCTIONS BASED ON THE COMPLETE DIS-ASSEMBLY OF THE MACHINE. SO, IT ALLOWING YOU TO STOP WASTING MONEY ON ROUTINE MAINTENANCE, AND GIVE YOU ALL THE SOLID INFORMATION AND GUIDANCE NEEDED TO PERFORM LARGER REPAIRS AND MODIFICATIONS AT HOME.