1、Designation: D5579 13Standard 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 cas
2、e 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. Scope*1.1 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, orreagents, 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-pound
6、 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 Th
7、is 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 method
8、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 Placement
9、 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 a
10、nd 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 For
11、ms 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 Eng
12、ine Oils in1This test method is under the jurisdiction of ASTM Committee D02 onPetroleum Products, Liquid Fuels, and Lubricants and is the direct responsibility ofSubcommittee D02.B0.03 on Automotive Gear Lubricants or when shiftingfrom low range to high range, for the countershaft speed todecrease
13、from (1700 to 500) r/min.3.2.6 synchronizer, na pack of friction and reaction platesused to match the speeds of the low- and high-range gears priorto engagement.3.2.7 unsynchronized shift, na shift in which the speed ofthe mating gears is not matched to the speed of the transmis-sion output shaft by
14、 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 andheating systems, are thoroughly cleaned. The transmission isrebuilt with a new synchronizer assembly, including measuredshifter fork, fr
15、iction, 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 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 andch
16、arged 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 is automatically cycled between lowand high range until two unsynchronized shifts occur or thedesired length of test is reached without f
17、ailure. 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 inspected. The shifter fork and friction plates aremeasured again to determine wear.5. Significance and Use5.1 This test method is used to eva
18、luate automotive manualtransmission fluids for thermal instability, which results indeterioration of synchronizer performance.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 o
19、f 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 Specification.6. Apparatus6.1 Table 1 is a list of the make and model of recommendedinstruments and equipment.6.2 Test TransmissionThe tes
20、t transmission is a MACKT2180, configuration 11KBA51431 (see Fig. 1). Some parts inthe transmission are to be removed and some are to be addedbefore testing, as listed in Table 2. The main box shift railcover can be replaced with an aluminum plate to facilitatetransmission cleaning at end of test.6.
21、3 Transmission MountsThe transmission is mounted asshown in Fig. 2.6.4 Oil-Circulating SystemThe system heats the oil to thespecified operating temperature of 250 6 5F (121 C 62.7 C) and maintains this temperature throughout the durationof the test. The power density of the heater is not high enough
22、to cause degradation of the oil (22 to 25 W/in.2(3.4 W/cm2to3.9 W/cm2). The oil flow rate is between 6 and 10 gal/min(23 L/min to 38 L/min). A layout of the oil-circulation systemis shown in Fig. 3. A detailed drawing of the recommended oilheating chamber is shown in Fig. 4. The total oil capacity o
23、f thetest system is 5.25 gal (19.87 L) with the oil level in thetransmission at the lower edge of the fill hole. If the systemcapacity is too small, increase by lengthening oil hoses. Whenthe system capacity is too great, decrease by shortening hoses,if it is practical to do so; otherwise, install a
24、n 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.4Available from Society of Automotive Engineers (SAE), 400 CommonwealthDr., Warrendale, PA 15096-0001.5Available from Standardization
25、 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.D5579 1326.5 Oil Return HoleDrill and tap a hole in the compoundcase for the oil to return after flowing throu
26、gh the heatexchanger. The location and size of this hole are shown in 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 pilot valve, which iscycled by a solenoid valve at a rate of 5 cpm.
27、 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 synchronizer to complete the shift. In the test stand,the transmi
28、ssion 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 torque, avibration in the drive line is intentionally excited. The dr
29、ivelineis 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 driveline at an angle.Alayoutshowing the offset of the transmission
30、 relative to the jack shaftis shown in Fig. 2.6.8 InstrumentationSupply sensors and displays, either onthe test console or in a data logging computer, as 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
31、shifting), and6.8.6 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 cente
32、rline of the 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 tempe
33、rature 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 D235, Type II, Class
34、 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 supplier.8. Safety8.1 The following are suggestions of procedu
35、res 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 facilit
36、ies 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 appr
37、oved by its safetydepartment. Personnel 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 o
38、perating, 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 always be worn by personnelworking on the transmissions. Loose o
39、r 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 clean and free of oilspills. In addition, the working area should be
40、free of alltripping hazards. In case of injury, no matter how slight, firstTABLE 1 Recommended 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 Indicati
41、onTemperature 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 supply gage U.S. Gage P44U, O-160 psiAir regulator Norgren
42、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 forkwear; manual transmis-sion lubricants; shifting synchronization; shift time; thermalstability; total cycle timeANNEXES(Mandatory Inf
43、ormation)A1. TEST VALIDITY CALCULATIONS AND LIMITSA1.1 For a test to be operationally valid it shall not exceedthe limits on unscheduled downtime, and deviation fromoperating parameters and average cycle time as follows.A1.1.1 Downtime Limits:A1.1.1.1 During Warm-upNo limit on number of occur-rences
44、 nor length of time down.A1.1.1.2 During test (regardless of length of test):(1) Occurrences less than 15-min durationnot counted,but reported.(2) Occurrences, over 15-min durationmaximum ofthree.(3) Total time down, no occurrence 16 h.A1.1.2 Deviation from Test Operating Parameters:A1.1.2.1 The fol
45、lowing operating parameters are consideredcritical to test validity.(1) Oil sump temperature,(2) Shift air supply pressure, and(3) Tailshaft speed.A1.1.2.2 Calculate the percent deviation as follows:percent out 5(i51nSMi0.5R3TiDD3100 (A1.1)where:Mi = magnitude of test parameter out from specificatio
46、nlimit at occurrence, i,R = test parameter specification range,Ti = length of time the test parameter was outside ofspecification range at occurrence, i,(Ti is assumed tobe no less than the recorded data-acquisition frequencyunless supplemental readings are documented), andD = test or test phase dur
47、ation in same units as Ti.NOTE A1.1A reading out of specification using once-per-hour datarecording is considered to be out for the full hour, unless otherwisedocumented.A1.1.2.3 The deviation percentages for the critical operatingparameters shall not exceed:Limits, %Oil sump temperature 2.0Shift ai
48、r supply pressure 2.0Tailshaft speed 5.0A1.1.2.4 As an example, assume:(1) Test length200 h,(2) Oil sump temperature250 6 5F (121 C 6 2.8 C):259F (126 C) for 1 h,(3) Oil sump temperature250 6 5F (121 C 6 2.8 C):244F (118 C) for 6 h,(4) Shift air supply press90 6 2 psi (620 kPa 6 14 kPa):93 psi (641
49、kPa) for 2 h, and(5) Tailshaft speed750 r/min 6 10 r/min. No out ofspecification readings.A1.1.2.5 Oil Temperature:45312003100 5 0.40%15362005 0.60% (A1.2)Total Deviation Percentage 5 0.40%10.60% 5 1.00%A1.1.2.6 Air Pressure:12322003100 5 0.50% (A1.3)A1.1.3 Average Cycle Time:A1.1.3.1 The average total cycle time for a complete testshall be within (12 6 0.6) s for the test to be consideredoperationally valid.Average Total Cycle Time5 (A1.4)3600 3total operating hours of testtotal cycles of testD5579 1310A1.1.3.2 The total cycle time is the time t
