MACK T310 Service Manual

TRANSMISSION

T310

SERVICE MANUAL

APRIL 2003

(NEW ISSUE)

10-126

front.fm Page -ii Thursday, December 19, 2002 10:54 AM

-ii

newknow.fm Page 1 Thursday, May 21, 1998 2:23 PM

Manual: _______________________________ Publication Number: _______ Vehicle Model: _________________________ Model Year: ______________ Do you find procedures properly organized and easy to follow? m Yes m No If not, please explain: ____________________________________ __________

___________________________________ ____________________________

PLEASE LET US KNOW!

Your comments and suggestions will help

us improve this manual!

Please complete and mail this form or FAX

your comments to: (610) 709-3800.

___________________________________ ____________________________ Manual page numbers: _____________________________________________ Are there any important procedures or other information presently not in this

manual that you would like to see included? m Yes m No If yes, please describe: _____________________________ ________________

___________________________________ ____________________________

___________________________________ ____________________________ Did you find any errors in the procedures or illustrations? m Yes m No If yes, what pages? _______________________________ ________________ Please explain: ___________________________________________________

_______________________________________________________________ Please include a copy of each page in question and mark your comments and

suggestions. Name: ________________________________ Phone: (_____) _____-_______ Company: _______________________________________________________ Address: ________________________________________________________ City: _________________________________ State: _______ Zip: _______ Position Title: ____________________________________ ________________

Thank You For Your Assistance

Mack Trucks, Inc.

(ATTENTION: RTS STAFF, 6S3)

DO NOT STAPLE — USE TRANSPARENT T A PE

Busreply.fm Page 1 Thursday, May 21, 1998 2:24 PM

FOLD ALONG THIS LINE • DO NOT STAPLE • USE TRANSPARENT TAPE

BUSINESS REPLY MAIL

FIRST CLASS MAIL PERMIT NO. 1602 ALLENTOWN, PA

POSTAGE WILL BE PAID BY ADDRE SS EE

SERVICE PUBLICATIONS (RTS), 6S3 MACK TRUCKS INC WORLD HEADQUARTERS PO BOX M ALLENTOWN PA 18105-9972

FOLD ALONG THIS LINE

NO POSTAGE

NECESSARY

IF MAILED

IN THE

UNITED STATES

TRANSMISSION

T310

SERVICE MANUAL

APRIL 2003 (NEW ISSUE)

10-126

front.fm Page ii Thursday, December 19, 2002 10:54 AM

ATTENTION

The information in this manual is not all inclusive and cannot take into account all unique situations. Note that some illustrations are typical and may not reflect the exact arrangement of every component installed on a specific chassis.

The information, specifications, and illustrations in this publication are based on information that was current at the time of publication.

No part of this publication may be reproduced, stored in a retrieval system, or be transmitted in any form by any means including (but not limited to) electronic, mechanical, photocopying, recording, or otherwise without prior written permission of Mack Trucks, Inc.

front.fm Page iii Thursday, December 19, 2002 10:54 AM

TABLE OF CONTENTS

iii

front.fm Page iv Thursday, December 19, 2002 10:54 AM

TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Advisory Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Service Procedures and Tool Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

EXPLANATION OF NUMERICAL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

VISUAL IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

TRANSMISSION IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Unit Identification Stamping Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

T310 Transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Gear Ratios and Shift Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

T310 Shifting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Power Flow Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

COMPONENT LOCATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

TROUBLESHOOTING CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

TRANSMISSION MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Checking Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Changing Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Change Interval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Draining Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Oil Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Magnetic Oil Filter Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Air Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

REPAIR INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

TRANSMISSION DISASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

TRANSMISSION COMPONENT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Main Case Shift Cover Disassembly [323] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Two-Position Range Shift Cylinder Disassembly [324] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

Range Shift Valve [323] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Main Drive Pinion Disassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Front Mainshaft Disassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Rear Mainshaft and Synchronizer Disassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Synchronizer Disassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Rear Mainshaft Bearing Cover Disassembly [321] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Compound Main Drive Gear Disassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Front Countershaft Front Bearing Cover Disassembly [321] . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Front Countershaft Disassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Front Countershaft Rear Bearing Cover Disassembly [321] . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Rear Countershaft Disassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Rear Countershaft Bearing Cover Disassembly [321] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Reverse Idler Gear Disassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

front.fm Page v Thursday, December 19, 2002 10:54 AM

INSPECTION OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Inspection and Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Bearings [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Gears [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Shifter Forks, Sliding Clutches and Shift Rails [323] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Oil Seals [321] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

General Reassembly Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

TRANSMISSION COMPONENT REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Reverse Idler Gear Reassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Rear Countershaft Bearing Cover Reassembly [321] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Rear Countershaft Reassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Front Countershaft Rear Bearing Cover Reassembly [321] . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Front Countershaft Reassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Front Countershaft Front Bearing Cover Reassembly [321] . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Compound Main Drive Gear Reassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Rear Mainshaft Bearing Cover Reassembly [321] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Synchronizer Reassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Rear Mainshaft Reassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Front Mainshaft Reassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Main Drive Pinion Reassembly [322] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Range Shift Valve [323] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Two-Position Range Shift Cylinder Reassembly [324] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Main Case Shift Cover Reassembly [323] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

TRANSMISSION REASSEMBLY PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

TABLE OF CONTENTS

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Gear Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Fits and Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

General Tolerances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Transmission Specifications and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

SCHEMATIC & ROUTING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

Air Piping Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

Air Control Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

SPECIAL TOOLS & EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

SPECIAL TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

DISASSEMBLED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

DISASSEMBLED VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

front.fm Page vi Thursday, December 19, 2002 10:54 AM

NOTES

10-126.bk Page 1 Thursday, December 19, 2002 10:55 AM

INTRODUCTION

Page 1

10-126.bk Page 2 Thursday, December 19, 2002 10:55 AM

INTRODUCTION

SAFETY INFORMATION

Advisory Labels

Cautionary signal words (Danger-Warning-Caution) may appear in various locations throughout this manual. Information accented by one of these signal words must be observed to minimize the risk of personal injury to service personnel, or the possibility of improper service methods which may damage the vehicle or cause it to be unsafe. Additional Notes and Service Hints are used to emphasize areas of procedural importance and provide suggestions for ease of repair. The following definitions indicate the use of these advisory labels as they appear throughout the manual:

Activities associated with Danger indicate that death or serious personal injury may result from failing to heed the advisory. Serious personal injury may be equated to career-ending injury.

Activities associated with Warning indicate that personal injury may result from failing to heed the advisory. In this case, personal injury is not equated to career-ending injury, but results in possible change in quality of life.

Activities associated with Caution indicate that product damage may result from failing to heed the advisory. Caution is not used for personal injury.

A procedure, practice, or condition that is essential to emphasize.

A helpful suggestion that will make it quicker and/or easier to perform a procedure, while possibly reducing service cost.

Page 2

10-126.bk Page 3 Thursday, December 19, 2002 10:55 AM

Service Procedures and Tool Usage

Anyone using a service procedure or tool not recommended in this manual must first satisfy himself thoroughly that neither his safety nor vehicle safety will be jeopardized by the service method he selects. Individuals deviating in any manner from the instructions provided assume all risks of consequential personal injury or damage to equipment involved.

Also note that particular service procedures may require the use of a special tool(s) designed for a specific purpose. These special tools must be used in the manner described, whenever specified in the instructions.

1. Before starting a vehicle, always be seated in the driver’s seat, place the transmission in neutral, be sure that parking brakes are set, and disengage the clutch.

INTRODUCTION

2. Before working on a vehicle, place the transmission in neutral, set the parking brakes, and block the wheels.

3. Before towing the vehicle, place the transmission in neutral and lift the rear wheels off the ground, or disconnect the driveline to avoid damage to the transmission during towing.

Engine-driven components such as Power Take-Off (PTO) units, fans and fan belts, driveshafts and other related rotating assemblies, can be very dangerous. Do not work on or service engine-driven components unless the engine is shut down. Always keep body parts and loose clothing out of range of these powerful components to prevent serious personal injury. Be aware of PTO engagement or nonengagement status. Always disengage the PTO when not in use.

REMEMBER,

SAFETY. . .IS NO ACCIDENT!

Page 3

10-126.bk Page 4 Thursday, December 19, 2002 10:55 AM

INTRODUCTION

Mack Trucks, Inc. cannot anticipate every possible occurrence that may involve a potential hazard. Accidents can be avoided by recognizing potentially hazardous situations and taking necessary precautions. Performing service procedures correctly is critical to technician safety and safe, reliable vehicle operation.

The following list of general shop safety practices can help technicians avoid potentially hazardous situations and reduce the risk of personal injury. DO NOT perform any services, maintenance procedures or lubrications until this manual has been read and understood.

r Perform all service work on a flat, level

surface. Block wheels to prevent vehicle from rolling.

r DO NOT wear loose-fitting or torn clothing.

Remove any jewelry before servicing vehicle.

r ALWAYS wear safety glasses and protective

shoes. Avoid injury by being aware of sharp corners and jagged edges.

r Use hoists or jacks to lift or move heavy

objects.

r NEVER run engine indoors unless exhaust

fumes are adequately vented to the outside.

r Be aware of hot surfaces. Allow engine to

cool sufficiently before performing any service or tests in the vicinity of the engine.

r Keep work area clean and orderly. Clean up

any spilled oil, grease, fuel, hydraulic fluid, etc.

r Only use tools that are in good condition,

and always use accurately calibrated torque wrenches to tighten all fasteners to specified torques. In instances where procedures require the use of special tools which are designed for a specific purpose, use only in the manner described in the instructions.

r Do not store natural gas powered vehicles

indoors for an extended period of time (overnight) without first removing the fuel.

r Never smoke around a natural gas powered

vehicle.

Page 4

10-126.bk Page 5 Thursday, December 19, 2002 10:55 AM

INTRODUCTION

EXPLANATION OF NUMERICAL CODE

The organization of MACK service manuals has been upgraded to standardize manual content according to a reference system based on component identification. The reference system helps link the information contained in this publication with related information included in other MACK service-warranty publications, such as associated service bulletins, warranty manuals, and MACK Service Labor Time Standards.

The system is based on a numerical code first digit of which identifies the general component grouping as listed here:

GROUP 000 — GENERAL DATA

GROUP 100 — CHASSIS

GROUP 200 — ENGINE

GROUP 300 — CLUTCH, TRANSMISSION, TRANSFER CASE AND PTO

, the

GROUP 400 — STEERING, AXLES, WHEELS AND TIRES, DRIVELINE

GROUP 500 — BRAKES, AUXILIARY SYSTEMS

GROUP 600 — CAB, TRUCK BODY

GROUP 700 — ELECTRICAL

The second two digits of the 3-digit code are used to identify the system, assembly or subassembly, as appropriate, within each of the groupings. The codes applicable to this publication are shown at the beginning of each procedure, as necessary, to guide you to specific component information.

Additionally, a two-character alpha code [GA] CASE, MAIN) may be shown with each operation. This alpha code, in combination with the three-digit Group number, identifies the specific assembly, subassembly or part, and directly relates to the first five positions of the operation code listed in the MACK Service Labor Time Standards.

(i.e.,

Example of Numerical Code

Page 5

10-126.bk Page 6 Thursday, December 19, 2002 10:55 AM

INTRODUCTION

CONVERSION CHART

Conversion Units Multiply By:

Length Calculations

Inches (in) to Millimeters (mm) 25.40

Inches (in) to Centimeters (cm) 2.540

Feet (ft) to Centimeters (cm) 30.48

Feet (ft) to Meters (m) 0.3048

Yards (yd) to Centimeters (cm) 91.44

Yards (yd) to Meters (m) 0.9144

Miles to Kilometers (km) 1.609

Millimeters (mm) to Inches (in) 0.03937

Centimeters (cm) to Inches (in) 0.3937

Centimeters (cm) to Feet (ft) 0.0328

Centimeters (cm) to Yards (yd) 0.0109

Meters (m) to Feet (ft) 3.281

Meters (m) to Yards (yd) 1.094

Kilometers (km) to Miles 0.6214

Area Calculations

Square Inches (sq-in) to Square Millimeters (sq-mm) 645.2

Square Inches (sq-in) to Square Centimeters (sq-cm) 6.452

Square Feet (sq-ft) to Square Centimeters (sq-cm) 929.0

Square Feet (sq-ft) to Square Meters (sq-m) 0.0929

Square Yards (sq-yd) to Square Meters (sq-m) 0.8361

Square Miles (sq-miles) to Square Kilometers (sq-km) 2.590

Square Millimeters (sq-mm) to Square Inches (sq-in) 0.00155

Square Centimeters (sq-cm) to Square Inches (sq-in) 0.155

Square Centimeters (sq-cm) to Square Feet (sq-ft) 0.001076

Square Meters (sq-m) to Square Feet (sq-ft) 10.76

Square Meters (sq-m) to Square Yards (sq-yd) 1.196

Square Kilometers (sq-km) to Square Miles (sq-miles) 0.3861

Volume Calculations

Cubic Inches (cu-in) to Cubic Centimeters (cu-cm) 16.387

Cubic Inches (cu-in) to Liters (L) 0.01639

Quarts (qt) to Liters (L) 0.9464

Gallons (gal) to Liters (L) 3.7854

Cubic Yards (cu-yd) to Cubic Meters (cu-m) 0.7646

Cubic Centimeters (cu-cm) to Cubic Inches (cu-in) 0.06102

Liters (L) to Cubic Inches (cu-in) 61.024

Liters (L) to Quarts (qt) 1.0567

Liters (L) to Gallons (gal) 0.2642

Cubic Meters (cu-m) to Cubic Yards (cu-yd) 1.308

Page 6

10-126.bk Page 7 Thursday, December 19, 2002 10:55 AM

Weight Calculations

Ounces (oz) to Grams (g) 28.5714

Pounds (lb) to Kilograms (kg) 0.4536

Pounds (lb) to Short Tons (US tons) 0.0005

Pounds (lb) to Metric Tons (t) 0.00045

Short Tons (US tons) to Pounds (lb) 2000

Short Tons (US tons) to Kilograms (kg) 907.18486

Short Tons (US tons) to Metric Tons (t) 0.90718

Grams (g) to Ounces (oz) 0.035

Kilograms (kg) to Pounds (lb) 2.205

Kilograms (kg) to Short Tons (US tons) 0.001102

Kilograms (kg) to Metric Tons (t) 0.001

Metric Tons (t) to Pounds (lb) 2205

Metric Tons (t) to Short Tons (US tons) 1.1023

Metric Tons (t) to Kilograms (kg) 1000

Force Calculations

Ounces Force (ozf) to Newtons (N) 0.2780

Pounds Force (lbf) to Newtons (N) 4.448

Pounds Force (lbf) to Kilograms Force (kgf) 0.456

Kilograms Force (kgf) to Pounds Force (lbf) 2.2046

Kilograms Force (kgf) to Newtons (N) 9.807

Newtons (N) to Kilograms Force (kgf) 0.10196

Newtons (N) to Ounces Force (ozf) 3.597

Newtons (N) to Pounds Force (lbf) 0.2248

Torque Calculations

Pound Inches (lb-in) to Newton Meters (N·m) 0.11298

Pound Feet (lb-ft) to Newton Meters (N·m) 1.3558

Pound Feet (lb-ft) to Kilograms Force per Meter (kgfm) 0.13825

Newton Meters (N·m) to Pound Inches (lb-in) 8.851

Newton Meters (N·m) to Pound Feet (lb-ft) 0.7376

Newton Meters (N·m) to Kilograms Force per Meter (kgfm) 0.10197

Kilograms Force per Meter (kgfm) to Pound Feet (lb-ft) 7.233

Kilograms Force per Meter (kgfm) to Newton Meters (N·m) 9.807

Radiator Specific Heat Dissipation Calculations

British Thermal Unit per Hour (BTU/hr) to Kilowatt per Degree Celsius (kW/°C) 0.000293

Kilowatt per Degree Celsius (kW/°C) to British Thermal Unit per Hour (BTU/hr) 3414.43

Temperature Calculations

Degrees Fahrenheit (°F) to Degrees Celsius (°C) (°F32) 0.556

Degrees Celsius (°C) to Degrees Fahrenheit (°F) (1.8 x °C) + 32

INTRODUCTION

Conversion Units Multiply By:

Page 7

10-126.bk Page 8 Thursday, December 19, 2002 10:55 AM

INTRODUCTION

Conversion Units Multiply By:

Pressure Calculations

Atmospheres (atm) to Bars (bar) 1.01325

Atmospheres (atm) to Kilopascals (kPa) 101.325

Bars (bar) to Atmospheres (atm) 0.98692

Bars (bar) to Kilopascals (kPa) 100

Bar (bar) to Pounds per Square Inch (psi) 14.5037

Inches of Mercury (in Hg) to Kilopascals (kPa) 3.377

Inches of Water (in H

Pounds per Square Inch (psi) to Kilopascals (kPa) 6.895

Pounds per Square Inch (psi) to Bar (bar) 0.06895

Kilopascals (kPa) to Atmospheres (atm) 0.00987

Kilopascals (kPa) to Inches of Mercury (in Hg) 0.29612

Kilopascals (kPa) to Inches of Water (in H

Kilopascals (kPa) to Pounds per Square Inch (psi) 0.145

Power Calculations

Horsepower (hp) to Kilowatts (kW) 0.74627

Kilowatts (kW) to Horsepower (hp) 1.34

Fuel Performance Calculations

Miles per Gallon (mile/gal) to Kilometers per Liter (km/L) 0.4251

Kilometers per Liter (km/L) to Miles per Gallon (mile/gal) 2.352

Velocity Calculations

Miles per Hour (mile/hr) to Kilometers per Hour (km/hr) 1.609

Kilometers per Hour (km/hr) to Miles per Hour (mile/hr) 0.6214

Volume Flow Calculations

Cubic Feet per Minute (cu-ft/min) to Liters per Minute (L/min) 28.32

Liters per Minute (L/min) to Cubic Feet per Minute (cu-ft/min) 0.03531

O) to Kilopascals (kPa) 0.2491

O) 4.01445

Page 8

10-126.bk Page 9 Thursday, December 19, 2002 10:55 AM

VISUAL IDENTIFICATION

Page 9

10-126.bk Page 10 Thursday, December 19, 2002 10:55 AM

VISUAL IDENTIFICATION

TRANSMISSION IDENTIFICATION

Figure 1 — Location of Identification Stamping on Left Side of Main Case

Unit Identification Stamping Location

The following model code information is stamped on the left side of the transmission, toward the rear of the main case. Refer to Figure 1.

1. Unit Symbol Identification T = transmission 3 = 300 series 10 = useable forward speeds

2. Transmission Serial No.

3. Transmission Assembly (Part) No. * = digits may vary

4. Specific variant of the base assembly number (variant to item No. 3)

Page 10

10-126.bk Page 11 Thursday, December 19, 2002 10:55 AM

VISUAL IDENTIFICATION

Figure 2 — Cutaway View of T310 Transmission

Page 11

10-126.bk Page 12 Thursday, December 19, 2002 10:55 AM

NOTES

Page 12

10-126.bk Page 13 Thursday, December 19, 2002 10:55 AM

DESCRIPTION AND OPERATION

Page 13

10-126.bk Page 14 Thursday, December 19, 2002 10:55 AM

DESCRIPTION AND OPERATION

T310 Transmissions

DESCRIPTION

The T310 transmission is a member of a new family of MACK transmissions designated as MAXITORQUE These transmissions are the next evolution of the durable triple-countershaft transmission. New features and product enhancements have been engineered into these transmissions to provide a wide range of advantages which include the following:

r New and revised gear ratios for greater

overall range and versatility

r Lower “LOs” in forward and reverse for

superior site maneuvering

r Improved shift quality through the use of a

new sliding clutch with a fine-pitch tooth design versus the coarse-pitch tooth design of previous transmissions

r Enhanced durability

r Weight reduction versus the previous series

transmissions

The T310 transmissions are triple-countershaft units. They consist of a compact main box which houses five non-synchronized forward-speed gear sets plus a reverse gear set. The rear case of the T310 transmission is also a triplecountershaft unit. The rear case consists of Lorange and Hi-range gear sets which are air controlled by an air shift selector located on the main shift lever.

ES (T300) Series transmissions.

All gears are of the spur-type design and are in constant mesh with mating gears. All shifting is done by forks and sliding clutches. The shift rails and forks are integral with the shift cover for the main case.

A single gear shift lever is used to shift through a standard “H” pattern. An air shift range selector, mounted on the gear shift lever, is also used for shifting the T310. The range selector directs air pressure to the compound air shift cylinder. Operating the selector causes a shift between Hi range or Lo range in the compound.

The T310 has 10 forward speeds and two reverse speeds. Each of the five forward speeds in the main case is used once with the compound in Lo range (first, second, third, fourth and fifth), and once more with the compound in Hi range (sixth, seventh, eighth, ninth and tenth). Reverse may be used in either Lo range or Hi range. See Figure 7.

The compound range shift is accomplished using a plate-type synchronizer, shifted by a range shift cylinder and a shift fork.

The six countershafts, three in the main case and three in the rear case, are equally spaced around the mainshafts. This design distributes the load equally among the countershafts, thus keeping normal deflection and gear tooth loading to a minimum.

The main case and the bell housing are a onepiece casting, made from aluminum and heattreated for strength.

The main case also has 6- and 8-bolt openings that allow for the addition of Power Take-Off (PTO) units. PTO operation is off the (53 tooth) countershaft fifth (10th) speed gear.

The bearings are housed in cast-iron bearing retainers (covers). Tapered roller bearings are used at each end of all transmission countershafts.

Page 14

Figure 3 — Equal Torque Distribution

10-126.bk Page 15 Thursday, December 19, 2002 10:55 AM

DESCRIPTION AND OPERATION

Lubrication

SPLASH LUBRICATION

All parts inside the transmission are lubricated by a splash-and-gravity system. To minimize churning, only the lower countershaft dips into the lubrication oil. As the gears on that countershaft spin, a constant spray of oil is directed to all internal parts of the transmission. The oil cools as it circulates over the aluminum case. Troughs and passages, cast into the inside of the case, capture and direct oil to the bearings.

Figure 4 — Splash Lubrication

TRANSMISSION CASE OIL COOLER LINE PLUGS

Figure 5 — Transmission Case Oil Cooler Line Plugs

1. Outlet Plastic Cap 2. Suction Tube Plug

MAGNETIC OIL FILTER

A magnetic oil filter assembly is built into the right side of the main case. It consists of a magnetic plug which removes ferrous metallic particles from the passing oil. After passing the magnetic plug, the oil is channelled upward to an outlet, where it returns (by gravity) down into the transmission case sump. The magnetic plug is removable from the outside of the transmission, without the necessity of draining the oil since this plug is above the oil level. The drain plug at the bottom of the case is also magnetic.

An integral oil cooler pump system has been developed for MACK T300 series transmissions. The oil cooler is optional for engine ratings under 400 hp and chassis ratings under 80,000 GVW. The oil cooler system is required when the engine rating is equal to or exceeds 400 hp, or the chassis rating is greater than 80,000 GVW.

On T310 transmissions that are not built with oil cooler pump systems, the tube line openings are plugged or capped. The main suction tube area contains a metal plug and the outlet fitting area receives a plastic cap.

Figure 6 — Plug Locations

1. Magnetic Filter Plug

2. Oil Temperature Sensor

3. Oil Drain Plug

4. Oil Fill and Level Plug

Page 15

10-126.bk Page 16 Thursday, December 19, 2002 10:55 AM

DESCRIPTION AND OPERATION

Gear Ratios and Shift Pattern

Figure 7 — T310 Gear Ratios and Shift Pattern

Gear Position (Main Box) Lo-Range Ratios Hi-Range Ratios

1/6 13.81 2.67

2/7 10.05 1.94

3/8 7.18 1.39

4/9 5.17 1.00

5/10 3.75 0.73

R/R 14.73 2.75

Page 16

10-126.bk Page 17 Thursday, December 19, 2002 10:55 AM

DESCRIPTION AND OPERATION

T310 Shifting Instructions

Make sure air pressure is at least 100 psi and unit is warmed before making range shifts. Always start in Lo range. This also applies to dynamometer testing. When the truck is stationary, do NOT shift into Hi range and then start moving the truck. Otherwise, damage to the synchronizer may result. To avoid transmission damage, do not change range while in reverse.

The T310 unit is a range-shifted transmission which has 10 forward “highway” speeds. This transmission features a Lo and Hi auxiliary compound section controlled by an air shift range selector located on the shift lever. The compound section is equipped with a synchronizer to facilitate Lo-/Hi-range shifting.

The Lo range provides five low ratios. Never attempt to move the vehicle from a stopped position in any gear higher than fifth speed gear. Depending on load, grade, or road conditions, it may be necessary to start in first, second, third or fourth speed gears. In Hi range there are five forward gears that can be shifted in the standard manner. Always remember, however, to double clutch whether moving up or down through these gears. Reverse gear can be used in Lo range or Hi range.

UPSHIFTING (NORMAL HIGHWAY)

DOWNSHIFTING (NORMAL HIGHWAY)

Shift from 10th speed gear down through the Hi range (9-8-7-6), double clutching through each gear. While still in sixth speed gear, flip the air shift range selector down to Lo range (preselect). Then move the shift lever through neutral to fifth speed gear. As the shift lever passes through neutral, the transmission is placed into Lo range. Then, shift down to fourth, third, second and first speed gears, double clutching between all gears.

r Always start in Lo range according to shift

marker plate instructions. Never start in a gear higher than fifth speed gear, even when dynamometer testing.

r When the truck is stationary, do not shift into

Hi range and then start moving the truck. Damage to the synchronizer can result.

r Be careful not to overspeed the engine

during downshifting. Damage to powertrain components may result.

r To avoid transmission damage, do not

change range while moving in reverse gear.

Power Flow Diagrams

The following illustrations show power flow through the T310 transmission in each gear range.

With the shift lever in neutral, flip the air shift range selector down to Lo range. Then shift the transmission into first gear. Shift up to second, third, fourth and fifth speed gears, double clutching between the gears. When maximum engine RPM has been reached in fifth gear, flip the air shift range selector up to Hi range (preselect). Then move the shift lever through neutral to sixth gear. As the shift lever passes through neutral, the transmission is placed into Hi range. Continue following the normal sequence (7-8-9-10), being sure to double clutch from one gear to the next.

Figure 8 — First Speed

Page 17

10-126.bk Page 18 Thursday, December 19, 2002 10:55 AM

DESCRIPTION AND OPERATION

Figure 9 — Second Speed

Figure 12 — Fifth Speed

Figure 11 — Fourth Speed

Figure 10 — Third Speed

Figure 13 — Sixth Speed

Figure 14 — Seventh Speed

Page 18

10-126.bk Page 19 Thursday, December 19, 2002 10:55 AM

DESCRIPTION AND OPERATION

Figure 15 — Eighth Speed

Figure 18 — Reverse Speed (Lo)

Figure 16 — Ninth Speed

Figure 19 — Reverse Speed (Hi)

Figure 17 — Tenth Speed

Page 19

10-126.bk Page 20 Thursday, December 19, 2002 10:55 AM

NOTES

Page 20

+ 175 hidden pages