1、Designation: D5579 10aStandard Test Method forEvaluating the Thermal Stability of Manual TransmissionLubricants in a Cyclic Durability Test1This standard is issued under the fixed designation D5579; the number immediately following the designation indicates the year oforiginal adoption or, in the ca
2、se of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. Asuperscript epsilon () indicates an editorial change since the last revision or reapproval.1. Scope1.1 This test method covers the thermal stability of fluids foruse in heavy duty manual transm
3、issions 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 Correlation of test results with tr
4、uck 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 method may be necessary due to
5、refinements 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.1.5 The values stated in inch-pou
6、nd units are to be regardedas standard. The values given in parentheses are mathematicalconversions to SI units that are provided for information onlyand are not considered standard.1.5.1 ExceptionWhen materials, products, or equipmentare available only in inch-pound units, SI units are omitted.1.6
7、This standard does not purport to address all of thesafety concerns, if any, associated with its use. It is theresponsibility 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 metho
8、d is arranged as follows:SectionScope 1Referenced Documents 2Terminology 3Summary of Test Method 4Significance and Use 5Apparatus 6Test Transmission 6.2Transmission Mounts 6.3Oil-Circulating System 6.4Oil Return Hole 6.5Air Pressure Controls 6.6Drive System 6.7Instrumentation 6.8Thermocouple Placeme
9、nt 6.9Reagents and Materials 7Safety 8Preparation of Apparatus 9Cleaning of Parts 9.1Assembly 9.2Calibration 10Transmission and Test Stand Calibration 10.1Reference Oils 10.2Reference Oil Test Frequency 10.3Instrumentation Calibration 10.4Shift Time Calibration 10.5Operating Procedure 11System Flush
10、 and Charge 11.1Test Operation 11.2Shut-Down Procedure 11.3Transmission Disassembly 11.4Determination of Test Results 12Failure Criteria 12.1Shifter Fork Wear 12.2Test Validity Determination 12.3Report 13Precision and Bias 14Keywords 15Test Validity Calculations and Limits Annex A1HTCT Test Report F
11、orms and Data Dictionary Annex A2Manual Transmission Cyclic Durability Test PartsInspection and Wear MeasurementsAnnex A32. Referenced Documents2.1 ASTM Standards:3D235 Specification for Mineral Spirits (Petroleum Spirits)(Hydrocarbon Dry Cleaning Solvent)D7422 Test Method for Evaluation of Diesel E
12、ngine Oils inT-12 Exhaust Gas Recirculation Diesel EngineE29 Practice for Using Significant Digits in Test Data toDetermine Conformance with Specifications2.2 SAE Standard:1This test method is under the jurisdiction of ASTM Committee D02 onPetroleum Products and Lubricants and is the direct responsi
13、bility of SubcommitteeD02.B0.03 on Automotive Gear Lubricants or when shifting from lowrange to high range, for the countershaft speed to decreasefrom (1700 to 500) r/min.3.2.6 synchronizera pack of friction and reaction platesused to match the speeds of the low- and high-range gears priorto engagem
14、ent.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, including the case and the oil-circulating a
15、ndheating 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 test stand.4.3 The transmission and oil s
16、ystem 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 test operating range.4.6 The transmission
17、 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, the test parts are removedand visually insp
18、ected. 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 performance.5.2 This test method may also be uti
19、lized 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, and5.2.4 Mack Truck GO-H Gear Lubricant
20、Specification.6. Apparatus6.1 Table 1 is a list of the make and model of recommendedinstruments and equipment.4Available from Society of Automotive Engineers (SAE), 400 CommonwealthDr., Warrendale, PA 15096-0001.5Available from Standardization Documents Order Desk, DODSSP, Bldg. 4,Section D, 700 Rob
21、bins Ave., Philadelphia, PA 19111-5098.6Available from Volvo Powertrain, North America, 13302 Pennsylvania Ave.,Hagerstown, MD 21742.TABLE 1 Recommended Test Stand ComponentsItem Manufacturer Part No.Panel MetersTailshaft rpm Newport P-6031D20DCountershaft rpm Newport P-6031D20DShift time Newport P-
22、6031D20DCoast down time Newport P-6031D20DControl IndicationTemperature controller Omron ESEX-AFTemperature indicator Newport INF-0-0-0-0-JFCycle counter 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 s
23、upply gage U.S. Gage P44U, O-160 psiAir regulator Norgren RO-8-300 RNMAShift solenoid Asco 8317G35, 3-waysolenoidMag. pickup Electro 3010AN12 VDC Power supply Sola SLS-12-017Air pressure switch Penn P61AG-1RelaysAC Potter otherwise, install an inert (stainlesssteel) block in the transmission main bo
24、x 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 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.
25、6.6 Air Pressure ControlsThe transmission is shifted byair pressure applied to alternating sides of the range shiftpiston. The air pressure is provided 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-shi
26、ftdata 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 torqueshelp 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 loa
27、ding on the input pinion. The torques,therefore, are not present, and shifting can be delayed. To helpthe synchronizer shift smoothly without the opposing 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
28、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 placing the driveline at an angle.Alayoutshowing the offset of the transmission relative to the jack shaftis shown in Fig. 2.6.8 InstrumentationSensors and
29、 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,6.8.3 Tail shaft speed,6.8.4 Air pressure (system),6.8.5 Air pressure (dynamic during shifting), and6.8.6 Coast down time.6.9 Thermocouple PlacementTra
30、nsmission 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 centerline of the transmission8.0 in. (203 mm) forward of the back wal
31、l 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 notNOTE 1Left side view.NOTE 2See Table 2 for references to letters in brackets.FIG. 1 Transmission Modified for TestingD5579 10a3exposed to excessive heat in the he
32、ater, place an additionalthermocouple to measure the oil temperature 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 m
33、eeting the require-ments of Specification D235, Type II, Class C for AromaticContent (0-2% vol), Flash Point (142F/61 C, 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
34、supplier.TABLE 2 Transmission Parts to Be Added or Removed Before TestingNOTELetters in brackets, , refer to locations indicated on Fig. 1.Parts to Be RemovedRails, forks, springs, and ball from themainbox shift cover AAll main box gearing B:Main shaft gears and thrust washersCountershaft assemblies
35、Sliding clutches Mack part numbers 320KB3136(2)320KB3137Aor Volvo part numbers 25101998(2)25503685Compound CSplitter clutch Mack part number 320KB3141Splitter piston Mack part number 336KC333 or Volvo part number 25125890Splitter fork Mack part number 575KB3378 or Volvo part number 25502825Bell Hous
36、ing DAll clutch related partsShafts Mack part number 604KC277A,604KC34Bor Volvo part number 25085391 N/AYoke Mack part number 301KD43B or Volvo part number 25128328Parts to Be AddedSpeedometer plug Mack part number 37KC12 or Volvo part number N/ASpeedometer washer Mack part number 37AX419 or Volvo p
37、art number 20704759Orifice to range valve Mack part number 63AX3466 or Volvo part number 25107528Replace cast iron piston housing coverwith fabricated steel cover EFIG. 2 Typical Layout of Drive SystemD5579 10a48. Safety8.1 The following are suggestions of procedures and equip-ment that may assist i
38、n 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 to a number of safety hazards. O
39、nly 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 by its safetydepartment. Person
40、nel working on the transmissions should beprovided with the proper tools, be alert to common sense safetypractices, and avoid contact with moving or hot transmissionparts, or both. Heavy-duty guards should be installed aroundthe driveline. When the test stand is operating, personnelshould be caution
41、ed 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 should always be worn by personnelworking on the transmissions. Loose or flowing clothing, longhair, or oth
42、er 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 kept clean and free of oilspills. In addition, the working area should be free of alltripping hazards. In case
43、 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 oil cannot be permittedto accumulate in the test area.8.5 A remote station for shutting off the motor, pump
44、, andheater is recommended. Fixed fire-protection equipmentshould be provided.8.6 Normal precautions should be taken when using flam-mable solvents for cleaning purposes. Make sure adequateventilation is provided and fire-fighting equipment is immedi-ately accessible.8.7 It is recommended that safet
45、ies be provided to shutdown the drive motor and oil heater when the followingconditions occur:8.7.1 Oil temperature in transmission sump becomes exces-sive,8.7.2 Oil temperature leaving the oil-heating chamber be-comes excessive,8.7.3 Oil-circulating system loses pressure,8.7.4 Motor over-speeds or
46、under-speeds, and8.7.5 The fire-protection system is activated.8.8 See Fig. 8 for a typical schematic of safety circuits.9. Preparation of Apparatus9.1 Cleaning of Parts:9.1.1 Transmission CaseThoroughly clean the transmis-sion case with a cleaning solvent (see 7.2) to remove any oil,sludge, or varn
47、ish deposits remaining from the previous testand then air dry.9.1.2 Gears, Shafts, SynchronizerRemove all sludge, var-nish, and deposits. Rinse with a cleaning solvent (see 7.2) andair dry.9.1.3 Heater, Oil-Circulating SystemFlush oil lines with acleaning solvent (see 7.2) to remove any previous tes
48、t oil andthen air dry. Disassemble the heater, clean, and air dry aftereach test. Check the heater periodically for leaks and replacewhen necessary.9.2 Assembly:9.2.1 GeneralAssemble all parts as instructed in theMack Transmission Service Manual T2130/2180,6exceptwhere the service manual applies to
49、parts that are modified forthis test method. Refer to Table 3 for a list of approved testhardware part numbers. Use test oil for lubricating parts duringassembly.9.2.2 New PartsObtain the following parts from an au-thorized Mack truck dealer. Install the new parts listed in Table4 for each test:9.2.2.1 Inspect the following parts after each test andreplace if worn or damaged:NumberRequiredMackPart No.VolvoPart No.Thrust Washer 3 223KD249 25500345Thrust Washer 2 223KD316A 25500919Clutch Housing 2 53KC486C 25502585High Range MainShaft Gear1 751KB4123 25
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