1、Designation: D 5579 06An American National StandardStandard Test Method forEvaluating the Thermal Stability of Manual TransmissionLubricants in a Cyclic Durability Test1This standard is issued under the fixed designation D 5579; the number immediately following the designation indicates the year ofo
2、riginal adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon (e) indicates an editorial change since the last revision or reapproval.1. Scope1.1 This test method covers the thermal stability of fluids for
3、use in heavy duty manual transmissions when operated at hightemperatures.1.2 The lubricant performance is measured by the numberof shifting cycles that can be performed without failure ofsynchronization when the transmission is operated while con-tinuously cycling between high and low range.1.3 Corr
4、elation of test results with truck transmission ser-vice has not been established. However, the procedure has beenshown to appropriately separate two transmission lubricants,which have shown satisfactory and unsatisfactory field perfor-mance in the trucks of one manufacturer.1.4 Changes in this test
5、 method may be necessary due torefinements in the procedure, obsolescence of parts, or re-agents, and so forth. These changes will be incorporated byInformation Letters issued by the ASTM Test MonitoringCenter (TMC).2The test method will be revised to show thecontent of all the letters, as issued.1.
6、5 The values stated in inch-pound units are to be regardedas standard. When materials, products, or equipment areavailable only in inch-pound units, SI units are omitted.1.6 This standard does not purport to address all of thesafety concerns, if any, associated with its use. It is theresponsibility
7、of the user of this standard to establish appro-priate safety and health practices and determine the applica-bility of regulatory limitations prior to use.1.7 This test method is arranged as follows:SectionScope 1Referenced Documents 2Terminology 3Summary of Test Method 4Significance and Use 5Appara
8、tus 6Test Transmission 6.2Transmission Mounts 6.3Oil-Circulating System 6.4Oil Return Hole 6.5Air Pressure Controls 6.6Drive System 6.7Instrumentation 6.8Thermocouple Placement 6.9Reagents and Materials 7Safety 8Preparation of Apparatus 9Cleaning of Parts 9.1Assembly 9.2Calibration 10Transmission an
9、d Test Stand Calibration 10.1Reference Oils 10.2Reference Oil Test Frequency 10.3Instrumentation Calibration 10.4Shift Time Calibration 10.5Operating Procedure 11System Flush and Charge 11.1Test Operation 11.2Shut-Down Procedure 11.3Transmission Disassembly 11.4Determination of Test Results 12Failur
10、e Criteria 12.1Shifter Fork Wear 12.2Test Validity Determination 12.3Report 13Precision and Bias 14Keywords 15Test Validity Calculations and Limits Annex A1Test Kit Parts Annex A2HTCT Test Report Forms and Data Dictionary Annex A3Manual Transmission Cyclic Durability Test PartsInspection and Wear Me
11、asurementsAnnex A42. Referenced Documents2.1 ASTM Standards:3D 235 Specification for Mineral Spirits (Petroleum Spirits)(Hydrocarbon Dry Cleaning Solvent)E29 Practice for Using Significant Digits in Test Data toDetermine Conformance with Specifications2.2 SAE Standard:SAE J308 Axle and Manual Transm
12、ission Lubricants41This test method is under the jurisdiction of ASTM Committee D02 onPetroleum Products and Lubricants and is the direct responsibility of SubcommitteeD02.B0 on Automotive Lubricants.Current edition approved May 1, 2006. Published May 2006. Originallyapproved in 1994. Last previous
13、edition approved in 2005 as D 557905.2ASTM Test Monitoring Center, 6555 Penn Ave., Pittsburgh, PA 15206-4489.This edition incorporates revisions in all Information Letters through No. 05-2.3For referenced ASTM standards, visit the ASTM website, www.astm.org, orcontact ASTM Customer Service at servic
14、eastm.org. For Annual Book of ASTMStandards volume information, refer to the standards Document Summary page onthe ASTM website.4Available from Society of Automotive Engineers (SAE), 400 CommonwealthDr., Warrendale, PA 15096-0001.1Copyright ASTM International, 100 Barr Harbor Drive, PO Box C700, Wes
15、t Conshohocken, PA 19428-2959, United States.2.3 Military Standard:MIL-L-2105 Lubricating Oil, Gear, Multipurpose52.4 Other Standard:GO-H Mack Trucks Oil,Gear: Multi-Purpose63. Terminology3.1 Definitions:3.1.1 wearthe loss of material from two or more surfacesin relative motion.3.2 Definitions of Te
16、rms Specific to This Standard:3.2.1 dual-range transmissiona type of transmission inwhich the driver first shifts through all of the mainbox gearratios in low range, and then shifts to high range and shiftsthrough the mainbox again. The section containing the high-low range is the compound section.3
17、.2.2 friction diska steel circular plate to which a frictionmaterial has been bonded.3.2.3 glazedthe condition of the friction disks whenprecipitates have filled the pores in the friction material,polishing the surface, and changing the frictional properties.3.2.4 reaction diska steel disk that mate
18、s with the frictiondisk during synchronization.3.2.5 shift timethe period of time required for the coun-tershaft speed to increase from 500 to 700 r/min (high-to-low)or from 1700 to 500 r/min (low-to-high) shift.3.2.6 synchronizera pack of friction and reaction platesused to match the speeds of the
19、low- and high-range gears priorto engagement.3.2.7 unsynchronized shifta shift in which the speed of themating gears is not matched to the speed of the transmissionoutput shaft by the synchronizer.4. Summary of Test Method4.1 Prior to each test run, the transmission is disassembledand all parts, inc
20、luding the case and the oil-circulating andheating systems, are thoroughly cleaned. The transmission isrebuilt with a new synchronizer assembly, including measuredshifter fork, friction, and reaction disks. All other worn ordefective parts are replaced.4.2 The rebuilt transmission is installed on a
21、test stand.4.3 The transmission and oil system are flushed with the testoil in accordance with the flush procedure.4.4 The flush oil is drained, and the test oil is measured andcharged to the transmission.4.5 The transmission is started and operated in low rangeuntil the oil temperature reaches the
22、test operating range.4.6 The transmission is automatically cycled between lowand high range until two unsynchronized shifts occur or thedesired length of test is reached without failure. The timerequired to shift from high range to low range is recorded eachhour.4.7 At the conclusion of the test, th
23、e test parts are removedand visually inspected. The shifter fork and friction plates aremeasured again to determine wear.5. Significance and Use5.1 This test method is used to evaluate automotive manualtransmission fluids for thermal instability, which results indeterioration of synchronizer perform
24、ance.5.2 This test method may also be utilized in other specifi-cations and classifications of transmission and gear lubricantssuch as the following:5.2.1 (final API designation of PG-1),5.2.2 Military Specification MIL-L-2105,5.2.3 SAE Information Report J308 Axle and ManualTransmission Lubricants,
25、 and5.2.4 Mack Truck GO-H Gear Lubricant Specification.6. Apparatus6.1 Table 1 is a list of the make and model of recommendedinstruments and equipment.6.2 Test TransmissionThe test transmission is a MACKT2180, configuration 11KBA51431 (see Fig. 1). Some parts inthe transmission are to be removed and
26、 some are to be addedbefore testing, as listed in Table 2. The main box shift rail covercan be replaced with an aluminum plate to facilitate transmis-sion cleaning at end of test.6.3 Transmission MountsThe transmission is mounted asshown in Fig. 2.6.4 Oil-Circulating SystemThe system heats the oil t
27、o thespecified operating temperature of 250 6 5F (121 6 2.7C)5Available from Standardization Documents Order Desk, DODSSP, Bldg. 4,Section D, 700 Robbins Ave., Philadelphia, PA 19111-5098.6Available from Volvo Powertrain, North America, 13302 Pennsylvania Ave.,Hagerstown, MD 21742.TABLE 1 Recommende
28、d Test Stand ComponentsItem Manufacturer Part No.Panel MetersTailshaft rpm Newport P-6031D20DCountershaft rpm Newport P-6031D20DShift time Newport P-6031D20DCoast down time Newport P-6031D20DControl IndicationTemperature controller Omron ESEX-AFTemperature indicator Newport INF-0-0-0-0-JFCycle count
29、er Redington P2-1006-115ACCycle timer Omron H5BR-B-AC100-240T/C selector switch Thermo Electric 33112Oil psi gage/safety Murphy A-20EO, O-30 psiAir supply gage U.S. Gage P44U, O-160 psiAir regulator Norgren RO-8-300 RNMAShift solenoid Asco 8317G35, 3-waysolenoidMag. pickup Electro 3010AN12 VDC Power
30、 supply Sola SLS-12-017Air pressure switch Penn P61AG-1RelaysAC Potter otherwise, install an inert (stainlesssteel) block in the transmission main box sump to raise the oillevel. Route the oil lines so that they will empty completelywhen draining the system.6.5 Oil Return HoleA hole shall be drilled
31、 and tapped inthe compound case for the oil to return after flowing throughthe heat exchanger. The location and size of this hole are shownin Fig. 5.6.6 Air Pressure ControlsThe transmission is shifted byair pressure applied to alternating sides of the range shiftpiston. The air pressure is provided
32、 by a pilot valve, which iscycled by a solenoid valve at a rate of 5 cpm. These cycles arerecorded by a counter, which provides the cycles to mis-shiftdata for the pass/fail criteria of the test. A typical air controlsystem is shown in Fig. 6.6.7 Drive SystemIn the truck operation, opposing torquesh
33、elp the synchronizer to complete the shift. In the test stand,the transmission is driven from the rear by an electric motorand belt drive with no loading on the input pinion. The torques,therefore, are not present, and shifting can be delayed. To helpthe synchronizer shift smoothly without the oppos
34、ing torque, avibration in the drive line is intentionally excited. The drivelineis set out of phase by rotating the yoke at one end of the shaftwith respect to the other by a one spline tooth offset (22). Thetransmission output shaft is offset from the shaft of the motoror jack shaft, thereby placin
35、g the driveline at an angle.Alayoutshowing the offset of the transmission relative to the jack shaftis shown in Fig. 2.6.8 InstrumentationSensors and displays, either on thetest console or in a data logging computer, are to be suppliedas follows:6.8.1 Oil sump temperature,6.8.2 Countershaft speed,6.
36、8.3 Tail shaft speed,6.8.4 Air pressure (system),6.8.5 Air pressure (dynamic during shifting), and6.8.6 Coast down time.NOTE 1Left side view.NOTE 2See Table 2 for references to letters in brackets.FIG. 1 Transmission Modified for TestingTABLE 2 Transmission Parts to Be Added or Removed BeforeTesting
37、NOTELetters in brackets, , refer to locations indicated on Fig. 1.Parts to Be RemovedRails, forks, springs, and ball from the mainbox shift cover AAll main box gesting B:Mainshaft gears and thrust washersCountershaft assembliesSliding clutches (320KB3136, (2)320KB3137A)Compound CSplitter clutch (320
38、KB3141)Splitter piston and fork (336KC333, 575KB3378)Bell Housing DAll clutch related partsShafts (604KC277A, 604KC34B)Yoke (301KD43B)Parts to Be AddedSpeedometer plug (37KC12) and washer (37AX419)Pipe extension,18 NPT and orifice (63AX3466) to Range ValveReplace cast iron piston housing cover with
39、fabricated steel cover ED55790636.9 Thermocouple PlacementTransmission sump tem-perature is measured in the compound section of the transmis-sion with a thermocouple and conventional display equipment.Drill and tap the compound case to accept the thermocouple ata position located along the centerlin
40、e of the transmission 8.0in. (203 mm) forward of the back wall of the main case.Position the tip of the thermocouple to extend 1.5 in. (38 mm)into the sump. As a means of ensuring that the oil is notexposed to excessive heat in the heater, place an additionalthermocouple to measure the oil temperatu
41、re leaving the heateras shown in Fig. 7.7. Reagents and Materials7.1 OilApproximately 12 gal (45.4 L) of test oil isrequired. The integrity of the test oil is the responsibility of theoil supplier.7.2 SolventUse only mineral spirits meeting the require-ments of Specification D 235, Type II, Class C
42、for AromaticContent (0-2% vol), Flash Point (142F/61C, min), and Color(not darker than +25 on Saybolt Scale or 25 on Pt-Co Scale).(WarningCombustible. Health hazard.) Obtain a Certificateof Analysis for each batch of solvent from the supplier.8. Safety8.1 The following are suggestions of procedures
43、and equip-ment that may assist in reducing safety hazards. No attempt hasbeen made to address all possible safety problems. The user ofthis test method is responsible for establishing appropriatesafety and health practices.8.2 The operating of transmission tests can expose person-nel and facilities
44、to a number of safety hazards. Only personnelwho are thoroughly trained and experienced in transmissiontesting should undertake the design, installation, and operationof transmission test stands.8.3 Each laboratory conducting transmission tests shouldhave its test installation inspected and approved
45、 by its safetydepartment. Personnel working on the transmissions should beFIG. 2 Typical Layout of Drive SystemFIG. 3 Schematic of Oil SystemD5579064provided with the proper tools, be alert to common sense safetypractices, and avoid contact with moving or hot transmissionparts, or both. Heavy-duty g
46、uards should be installed aroundthe driveline. When the test stand is operating, personnelshould be cautioned against working alongside the transmis-sion and drivelines.All oil lines and electrical wiring should beproperly routed and grounded, guarded, and kept in good order.Safety masks or glasses
47、should always be worn by personnelworking on the transmissions. Loose or flowing clothing, longhair, or other accessories to dress that could become entangled,should not be worn near rotating equipment.8.4 The external parts of the transmission and the floor areaaround the transmission should be kep
48、t clean and free of oilspills. In addition, the working area should be free of alltripping hazards. In case of injury, no matter how slight, firstaid attention should be applied at once and the incidentreported. Personnel should be alert for leaking oil, whichrepresents a fire hazard. Containers of
49、oil cannot be permittedto accumulate in the test area.NOTE 1Material 1018 is similar material.NOTE 2All dimensions are in inches, unless otherwise noted.FIG. 4 Typical Oil Heater ChamberNOTEFigure is not drawn to scale.FIG. 5 Oil Return Hole LocationFIG. 6 Air Control and Supply SystemFIG. 7 Location of Oil Out-of-Heater Thermocouple, PressureRegulator, and SensorD55790658.5 A remote station for shutting off the motor, pump, andheater is recommended. Fixed fire-protection equipmentshould be provided.8.6 Normal precautions should be taken w
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