TRANSMISSION
T310
S E R V I C E M A N U A L
APRIL 2003 (NEW ISSUE)
10-126
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TRANSMISSION
T310
SERVICE MANUAL
APRIL 2003 |
© MACK TRUCKS, INC. 2003 |
|
(NEW ISSUE) |
10-126 |
|
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|
|
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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.
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TABLE OF CONTENTS
TABLE OF CONTENTS
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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
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TABLE OF CONTENTS
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
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
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NOTES
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INTRODUCTION
INTRODUCTION
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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.
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INTRODUCTION
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.
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!
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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.
rPerform all service work on a flat, level surface. Block wheels to prevent vehicle from rolling.
rDO NOT wear loose-fitting or torn clothing. Remove any jewelry before servicing vehicle.
rALWAYS wear safety glasses and protective shoes. Avoid injury by being aware of sharp corners and jagged edges.
rUse hoists or jacks to lift or move heavy objects.
rNEVER run engine indoors unless exhaust fumes are adequately vented to the outside.
rBe aware of hot surfaces. Allow engine to cool sufficiently before performing any service or tests in the vicinity of the engine.
rKeep work area clean and orderly. Clean up any spilled oil, grease, fuel, hydraulic fluid, etc.
rOnly 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.
rDo not store natural gas powered vehicles indoors for an extended period of time (overnight) without first removing the fuel.
rNever smoke around a natural gas powered vehicle.
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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, the 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
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 (i.e., [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.
Example of Numerical Code
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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
INTRODUCTION
|
Conversion Units |
Multiply By: |
||
|
|
|
|
|
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 |
|
|
|
|
|
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 H2O) |
|
to |
Kilopascals (kPa) |
0.2491 |
|
|
|
|
|
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 H2O) |
4.01445 |
|
|
|
|
|
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 |
|
|
|
|
|
Page 8
10-126.bk Page 9 Thursday, December 19, 2002 10:55 AM
VISUAL IDENTIFICATION
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
DESCRIPTION AND OPERATION
Page 13
10-126.bk Page 14 Thursday, December 19, 2002 10:55 AM
DESCRIPTION AND OPERATION
DESCRIPTION AND
OPERATION
T310 Transmissions
DESCRIPTION
The T310 transmission is a member of a new family of MACK transmissions designated as MAXITORQUE® ES (T300) Series transmissions. 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:
rNew and revised gear ratios for greater overall range and versatility
rLower “LOs” in forward and reverse for superior site maneuvering
rImproved 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
rEnhanced durability
rWeight 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.
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.
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.
Figure 3 — Equal Torque Distribution
Page 14
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
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 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.
Figure 6 — Plug Locations
1. |
Magnetic Filter Plug |
3. |
Oil Drain Plug |
2. |
Oil Temperature Sensor |
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)
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.
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.
rAlways start in Lo range according to shift marker plate instructions. Never start in a gear higher than fifth speed gear, even when dynamometer testing.
rWhen the truck is stationary, do not shift into Hi range and then start moving the truck. Damage to the synchronizer can result.
rBe careful not to overspeed the engine during downshifting. Damage to powertrain components may result.
rTo 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.
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 10 — Third Speed |
|
Figure 13 — Sixth Speed |
|
|
|
|
|
|
Figure 11 — Fourth 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
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