1、Designation: D 5579 09An 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 () indicates an editorial change since the last revision or reapproval.1. Scope1.1 This test method covers the thermal stability of fluids foru
3、se 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 Corre
4、lation 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.1.5
6、 The values stated in inch-pound 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 un
7、its, 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 of the user of this standard to establish appro-priate safety and health practices and determine the applica-bility of regulatory limitations pr
8、ior to use.1.7 This test method 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 6.7Instrumen
9、tation 6.8Thermocouple Placement 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 10.5Oper
10、ating Procedure 11System Flush 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 Lim
11、its Annex A1Test Kit Parts Annex A2HTCT Test Report Forms and Data Dictionary Annex A3Manual Transmission Cyclic Durability Test PartsInspection and Wear MeasurementsAnnex A42. Referenced Documents2.1 ASTM Standards:3D 235 Specification for Mineral Spirits (Petroleum Spirits)(Hydrocarbon Dry Cleanin
12、g Solvent)E29 Practice for Using Significant Digits in Test Data toDetermine Conformance with Specifications2.2 SAE Standard:SAE J308 Axle and Manual Transmission Lubricants41This test method is under the jurisdiction of ASTM Committee D02 onPetroleum Products and Lubricants and is the direct respon
13、sibility of SubcommitteeD02.B0.03 on Automotive Gear Lubricants 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 and ta
14、pped 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 by a p
15、ilot 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 torqueshelp the
16、 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 opposing tor
17、que, 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 placing the d
18、riveline 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,6.8.3 Tai
19、l shaft speed,6.8.4 Air pressure (system),6.8.5 Air pressure (dynamic during shifting), andNOTE 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 BeforeTestingNOTELetters in brackets, , re
20、fer 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 (320KB3141)Splitter piston and fo
21、rk (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 fabricated steel cover ED5579
22、0936.8.6 Coast down time.6.9 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 centerline of th
23、e transmission8.0 in. (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 temperature leav
24、ing 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 for Aro
25、maticContent (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 supplier.8. Safety8.1 The following are suggestions of procedures and eq
26、uip-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 to a n
27、umber 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 by it
28、s safetydepartment. Personnel working on the transmissions should beprovided with the proper tools, be alert to common sense safetyFIG. 2 Typical Layout of Drive SystemFIG. 3 Schematic of Oil SystemD5579094practices, and avoid contact with moving or hot transmissionparts, or both. Heavy-duty guards
29、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 should
30、 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 kept clea
31、n 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 oil ca
32、nnot 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 O
33、il Out-of-Heater Thermocouple, PressureRegulator, and SensorD55790958.5 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 when using flam-mable solvents for cleaning purposes. Make sur
34、e adequateventilation is provided and fire-fighting equipment is immedi-ately accessible.8.7 It is recommended that safeties 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 l
35、eaving the oil-heating chamber be-comes excessive,8.7.3 Oil-circulating system loses pressure,8.7.4 Motor over-speeds or 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 Tra
36、nsmission CaseThoroughly clean the transmis-sion case with a cleaning solvent (see 7.2) to remove any oil,sludge, or varnish 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) a
37、ndair dry.9.1.3 Heater, Oil-Circulating SystemFlush oil lines with acleaning solvent (see 7.2) to remove any previous test 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 GeneralAssem
38、ble all parts as instructed in theMack Transmission Service Manual T2130/2180,6exceptwhere the service manual applies to parts that are modified forthis test method. Use the part numbers identified in Table 3 forthe appropriate hardware configuration. Use test oil for lubri-cating parts during assem
39、bly. For all tests (reference andnon-reference oil) starting after June 9, 1999, use only hard-ware listed under Configurations 1 or 2 in Table 3.9.2.2 New PartsObtain the following parts from an au-thorized Mack truck dealer. Install the following new parts foreach test:NumberRequiredMackPart No.Ki
40、t (Parts in this kit are listed in Annex A2) 1 377SH21Friction Plate 8 N/A7Range Fork 1 575KB457Low Range Mainshaft Hab 1 84KC47(Configuration 2only)9.2.2.1 Inspect the following parts after each test andreplace if worn or damaged:Number Required Mack Part No.Thrust Washer 3 223KD249Thrust Washer 2
41、223KD316AClutch Housing 2 53KC486CHigh Range Mainshaft Gear 1 751kB4123(Configuration 2only)7Friction Plates are Wellman Item No. TESTWMPC5460.FIG. 8 Typical Schematics of Safety CircuitsTABLE 3 Part Numbers for Approved ConfigurationsTest Hardware ConfigurationPart description Configuration 1 Confi
42、guration 2Synchronizer clutch assembly 320KB450C 320KB459ASynchronizer pin (3 each) 301KC240B 301KC33Synchronizer pin (3 each) 301KC241B 301KC34Synchronizer pin (3 each) 48AX17 301KC35Synchronizer pre-load spring (3 each) 107KD244 107KD247High range mainshaft gear 751KB489 751KB4123Low range mainsha
43、ft hub 84KC42 84KC47Compound mainshaft, rear 601KC429 601KC432Bearing, compound mainshaft None required 46AX538Thrust washers, mainshaft (2 each) 223KD316A None requiredSnap ring (2 each) 97AX151 or97AX17197AX151 or97AX171Snap ring (2 each) 97AX267 97AX267Shift rail 591KC3154A 591KC3154AO-ring, low
44、range shift piston 56AX560 56AX560Piston, high low range shiftA336KC318 336KC318Cylinder housing, hi-lo shift piston 55KC46A 55KC46AO-ring, compound shift piston None required None requiredO-ring, range high low shift piston 56AX588 56AX588Countershaft gear, front 757KB3322757KB4108757KB3322757KB410
45、8Countershaft gear, rear 757KB4106757KB440A757KB4106Range shift valve 216KD123 216KD42AThe piston, high low range shift, has an outside diameter of 3.740 to 3.738 in.(95.00 to 94.95 mm).D55790969.2.3 Inspection of Air ValvesInspect the piston of therange shift valve and the fork air cylinder and rep
46、lace ifdamaged or visibly worn. Replace the O-rings in these valveswhen nicked, cut, softened, or hardened. However, replacethese O-rings at least every six months. Install a116-in. thickshim between the shaft cylinder and the transmission case forConfiguration 2 tests.9.2.4 Pre-test MeasurementsMea
47、sure the range fork forhardness and thickness at the locations shown in Fig.A4.1. Thehardness of the fork pads shall be a minimum of 55 Rcat eachof the four locations. Mark the friction disks on the spline tangswith an etching tool at three locations equally spaced. Measureand record the pad thickne
48、ss at these locations in the DataDictionary (see Annex A3).9.2.4.1 This hardness is greater than the manufacturingminimum. Some parts meeting the manufacturing specificationmay be rejected for this test method.9.2.5 Countershaft Bearing PreloadMeasure the pre-loadon each of the three countershafts p
49、rior to each test as follows:9.2.5.1 Assemble the transmission as specified in the MackTransmission Service Manual up to and including installing theyoke on the output shaft. Rotate the transmission so that theshafts are vertical.9.2.5.2 Remove the bearing cap from the rear cover for thefirst countershaft to be checked. Measure the thickness of a0.010-in. (0.254 mm) nominal shim, and record. Add the shimto the shim pack of the shaft, and reinstall the bearing cap.Torque the bolts to 40 to 50 lb-ft (54 Nm to 68 Nm).9.2.5.3 Mount a dial indicator
