1、Designation: D5579 13D5579 14Standard 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
2、 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. Scope*1.1 This test method covers the thermal stability of fluids for use in heavy duty manu
3、al transmissions when operated at hightemperatures.1.2 The lubricant performance is measured by the number of shifting cycles that can be performed without failure ofsynchronization when the transmission is operated while continuously cycling between high and low range.1.3 Correlation of test result
4、s with truck transmission service has not been established. However, the procedure has been shownto appropriately separate two transmission lubricants, which have shown satisfactory and unsatisfactory field performance in thetrucks of one manufacturer.1.4 Changes in this test method may be necessary
5、 due to refinements in the procedure, obsolescence of parts, or reagents, andso forth. These changes will be incorporated by Information Letters issued by theASTM Test Monitoring Center (TMC).2 The testmethod will be revised to show the content of all the letters, as issued.1.5 The values stated in
6、inch-pound units are to be regarded as standard. The values given in parentheses are mathematicalconversions to SI units that are provided for information only and are not considered standard.1.5.1 ExceptionWhen materials, products, or equipment are available only in inch-pound units, SI units are o
7、mitted.1.6 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibilityof the user of this standard to establish appropriate safety and health practices and determine the applicability of regulatorylimitations prior to use.1.7 This t
8、est method is arranged as follows:1 This test method is under the jurisdiction ofASTM Committee D02 on Petroleum Products, Liquid Fuels, and Lubricants and is the direct responsibility of SubcommitteeD02.B0.03 on Automotive Gear Lubricants or when shifting from low range to high range, for the count
9、ershaft speed to decrease from(1700 to 500) r/min.3.2.6 synchronizer, na pack of friction and reaction plates used to match the speeds of the low- and high-range gears prior toengagement.3.2.7 unsynchronized shift, na shift in which the speed of the mating gears is not matched to the speed of the tr
10、ansmissionoutput shaft by the synchronizer.4. Summary of Test Method4.1 Prior to each test run, the transmission is disassembled and all parts, including the case and the oil-circulating and heatingsystems, are thoroughly cleaned. The transmission is rebuilt with a new synchronizer assembly, includi
11、ng measured shifter fork,friction, and reaction disks. All other worn or defective 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 test oil in accordance with the flush procedure.4.4 The flush oil is drained, and t
12、he test oil is measured and charged to the transmission.4.5 The transmission is started and operated in low range until the oil temperature reaches the test operating range.4.6 The transmission is automatically cycled between low and high range until two unsynchronized shifts occur or the desiredlen
13、gth of test is reached without failure. The time required to shift from high range to low range is recorded each hour.4.7 At the conclusion of the test, the test parts are removed and visually inspected. The shifter fork and friction plates aremeasured again to determine wear.5. Significance and Use
14、5.1 This test method is used to evaluate automotive manual transmission fluids for thermal instability, which results indeterioration of synchronizer performance.5.2 This test method may also be utilized in other specifications and classifications of transmission and gear lubricants such asthe follo
15、wing: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 Manual Transmission 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 recommended instruments and e
16、quipment.6.2 Test TransmissionThe test transmission is a MACK T2180, configuration 11KBA51431 (see Fig. 1). Some parts in thetransmission are to be removed and some are to be added before testing, as listed in Table 2. The main box shift rail cover canbe replaced with an aluminum plate to facilitate
17、 transmission cleaning at end of test.6.3 Transmission MountsThe transmission is mounted as shown in Fig. 2.6.4 Oil-Circulating SystemThe system heats the oil to the specified operating temperature of 250 6 5F (121 C 6 2.7 C)and maintains this temperature throughout the duration of the test. The pow
18、er density of the heater is not high enough to causedegradation of the oil (22 to 25 W/in.2 (3.4 W/cm2 to 3.9 W/cm2). The oil flow rate is between 6 and 10 gal/min (23 L/min to38 L/min). A layout of the oil-circulation system is shown in Fig. 3. A detailed drawing of the recommended oil heating cham
19、beris shown in Fig. 4. The total oil capacity of the test system is 5.25 gal (19.87 L) with the oil level in the transmission at the loweredge of the fill hole. If the system capacity is too small, increase by lengthening oil hoses. When the system capacity is too great,decrease by shortening hoses,
20、 if it is practical to do so; otherwise, install an inert (stainless steel) block in the transmission mainbox sump to raise the oil level. Route the oil lines so that they will empty completely when draining the system.6.5 Oil Return HoleDrill and tap a hole in the compound case for the oil to retur
21、n after flowing through the heat exchanger.The location and size of this hole are shown in Fig. 5.D5579 1436.6 Air Pressure ControlsThe transmission is shifted by air pressure applied to alternating sides of the range shift piston. Theair pressure is provided by a pilot valve, which is cycled by a s
22、olenoid valve at a rate of 5 cpm. These cycles are recorded by acounter, which provides the cycles to mis-shift data for the pass/fail criteria of the test. A typical air control system is shown inFig. 6.6.7 Drive SystemIn the truck operation, opposing torques help the synchronizer to complete the s
23、hift. In the test stand, thetransmission is driven from the rear by an electric motor and belt drive with no loading on the input pinion. The torques, therefore,are not present, and shifting can be delayed. To help the synchronizer shift smoothly without the opposing torque, a vibration inthe drive
24、line is intentionally excited. The driveline is set out of phase by rotating the yoke at one end of the shaft with respectto the other by a one spline tooth offset (22). The transmission output shaft is offset from the shaft of the motor or jack shaft,thereby placing the driveline at an angle. A lay
25、out showing the offset of the transmission relative to the jack shaft is shown in Fig.2.6.8 InstrumentationSupply sensors and displays, either on the 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 (
26、system),6.8.5 Air pressure (dynamic during shifting), and6.8.6 Coast down time.6.9 Thermocouple PlacementTransmission sump temperature is measured in the compound section of the transmission witha thermocouple and conventional display equipment. Drill and tap the compound case to accept the thermoco
27、uple at a positionlocated along the centerline of the transmission 8.0 in. (203 mm) forward of the back wall of the main case. Position the tip ofthe thermocouple to extend 1.5 in. (38 mm) into the sump. As a means of ensuring that the oil is not exposed to excessive heatin the heater, place an addi
28、tional thermocouple to measure the oil temperature leaving the heater as shown in Fig. 7.7. Reagents and Materials7.1 OilApproximately 12 gal (45.4 L) of test oil is required. The integrity of the test oil is the responsibility of the oil supplier.TABLE 1 Recommended Test Stand ComponentsItem Manufa
29、cturer 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 counter Redington P2-1006-115ACCycle ti
30、mer 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 supply Sola SLS-12-017Air pressur
31、e switch Penn P61AG-1RelaysAC Potter forkwear; manual transmission lubricants; shifting synchronization; shift time; thermal stability;total cycle timeANNEXES(Mandatory Information)A1. TEST VALIDITY CALCULATIONS AND LIMITSA1.1 For a test to be operationally valid it shall not exceed the limits on un
32、scheduled downtime, and deviation from operatingparameters and average cycle time as follows.TABLE 5 Reference Oil PrecisionAVariable Intermediate Precision ReproducibilitySi.p.B i.p.C SRB RCCycles to Fail 9131 25567 9131 25567A These statistics are based on results obtained onTMC Reference Oils 151
33、-2 and151-3 with Configuration 2 hardware over the period from Jan. 25, 1999 throughMarch 19, 2005.B S = standard deviation.C This value is obtained by multiplying the standard deviation by 2.8.D5579 1413A1.1.1 Downtime Limits:A1.1.1.1 During Warm-upNo limit on number of occurrences nor length of ti
34、me 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 of three.(3) Total time down, no occurrence 16 h.A1.1.2 Deviation from Test Operating Parameters:A1.1.2.1 The following operatin
35、g parameters are considered critical 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 out5(i51n S Mi0.5R 3TiDD 3100 (A1.1)where:Mi = magnitude of test parameter out from specification limit at
36、occurrence, i,R = test parameter specification range,Ti = length of time the test parameter was outside of specification range at occurrence, i, (Ti is assumed to be no less than therecorded data-acquisition frequency unless supplemental readings are documented), andD = test or test phase duration i
37、n same units as Ti.NOTE A1.1A reading out of specification using once-per-hour data recording is considered to be out for the full hour, unless otherwise documented.A1.1.2.3 The deviation percentages for the critical operating parameters shall not exceed:Limits, %Oil sump temperature 2.0Shift air su
38、pply 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 k
39、Pa) for 2 h, and(5) Tailshaft speed750 r/min 6 10 r/min. No out of specification readings.A1.1.2.5 Oil Temperature:4531200310050.40%153620050.60% (A1.2)Total Deviation Percentage50.40%10.60%51.00%A1.1.2.6 Air Pressure:1232200310050.50% (A1.3)A1.1.3 Average Cycle Time:D5579 1414A1.1.3.1 The average t
40、otal cycle time for a complete test shall be within (1260.6) s for the test to be considered operationallyvalid.Average Total Cycle Time5 (A1.4)36003total operating hours of testtotal cycles of testA1.1.3.2 The total cycle time is the time to complete shifts from low range to high range and back to
41、low rangenominally 12s.A2. HTCT TEST REPORT FORMS AND DATA DICTIONARYA2.1 The required report forms and data dictionary are available on the ASTM Test Monitoring Center web page athttp:/www.astmtmc.cmu.edu/, or they can be obtained in hardcopy format from the TMC.Form 0 Test Report CoverForm 1 Test
42、Results Summary PageForm 2 Test Conditions and Measurements SummaryForm 3 Downtime and Comments SheetForm 4 Shift GraphsForm 5 Shift Time GraphsA3. MANUAL TRANSMISSION CYCLIC DURABILITY TEST PARTS INSPECTION AND WEAR MEASUREMENTSA3.1 Figs. A3.1-A3.4 are examples of the necessary report forms.D5579 1
43、415FIG. A3.1 Typical Form for Recording Friction Disk WearD5579 1416NOTE 1Side of fork with forged angle and part number is the rear side. View the fork from this side to identify the pads as left and right.NOTE 2Post-test wear measurement may be made at EOT or at passing cycles. See “Cycles at Wear
44、 Measurement” for the point at which the post-testwear measurement was taken.FIG. A3.2 Typical Form for Recording Fork Pad Thickness Wear MeasurementsD5579 1417FIG. A3.3 Typical Form for Recording Preload MeasurementsD5579 1418NOTE 1Log all shutdowns and repairs on the back of the log sheet.FIG. A3.
45、4 Data Log SheetD5579 1419SUMMARY OF CHANGESSubcommittee D02.B0 has identified the location of selected changes to this standard since the last issue(D5579 12aD5579 13) that may impact the use of this standard. (Approved Oct. 1, 2013May 1, 2014.)(1) Subsections Subsection 9.2.2.110.2 andelaborates 9
46、.2.3 andon reasons Table 3 andfor testing Table 4 have been modified toinclude new range clutch synchronizer components.reference oils.(2) Subsection 10.3 revises the frequency of reference oil testing.Subcommittee D02.B0 has identified the location of selected changes to this standard since the las
47、t issue(D5579 12D5579 12a) that may impact the use of this standard. (Dec.(Oct. 1, 2012.)2013.)(1) Editorially improvedSubsections 9.2.2.1 the standard by applying Form and Styleand 9.2.3 (including SIand Table 3 10)andTable 5guidelines. have been modified to include new range clutch synchronizer co
48、mponents.ASTM International takes no position respecting the validity of any patent rights asserted in connection with any item mentionedin this standard. Users of this standard are expressly advised that determination of the validity of any such patent rights, and the riskof infringement of such ri
49、ghts, are entirely their own responsibility.This standard is subject to revision at any time by the responsible technical committee and must be reviewed every five years andif not revised, either reapproved or withdrawn.Your comments are invited either for revision of this standard or for additional standardsand should be addressed to ASTM International Headquarters. Your comments will receive careful consideration at a meeting of theresponsible technical committee, which you may attend. If you feel that your comments have
