1、Designation: D5579 14D5579 15Standard 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.INTRODUCTIONThis test method is written for use by laboratories that use the portions of the te
3、st method that refertoASTM Test Monitoring Center (TMC) services (seeAnnexA1). Laboratories that choose not to usethe TMC services may simply disregard these portions.The TMC provides reference oils, and engineering and statistical services to laboratories that desireto produce test results that are
4、 statistically similar to those produced by laboratories previouslycalibrated by the TMC.In general, the Test Purchaser decides if a calibrated test stand is to be used. Organizations such asthe American Chemistry Council require that a laboratory use the TMC services as part of their testregistrati
5、on process. In addition, the American Petroleum Institute and the Gear Lubricant ReviewCommittee of the Lubricant Review Institute (SAE International) require that a laboratory use theTMC services in seeking qualification of oils against their specifications.NOTE 1The advantage of using the TMC serv
6、ices to calibrate test stands is that the test laboratory (and hence theTest Purchaser) has an assurance that the test stand was operating at the proper level of test severity. It should also beborne in mind that results obtained in a non calibrated test stand may not be the same as those obtained i
7、n a test standparticipating in the ASTM TMC services process.1. Scope*1.1 This test method covers the thermal stability of fluids for use in heavy duty manual transmissions when operated at hightemperatures.1.2 The lubricant performance is measured by the number of shifting cycles that can be perfor
8、med without failure ofsynchronization when the transmission is operated while continuously cycling between high and low range.1.3 Correlation of test results with truck transmission service has not been established. However, the procedure has been shownto appropriately separate two transmission lubr
9、icants, which have shown satisfactory and unsatisfactory field performance in thetrucks of one manufacturer.1.4 Changes in this test method may be necessary due to refinements in the procedure, obsolescence of parts, or reagents, andso forth. These changes will be incorporated by Information Letters
10、 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 inch-pound units are to be regarded as standard. The values given in parentheses are mathematicalconversions to SI units that are provided for i
11、nformation only and are not considered standard.1.5.1 ExceptionWhen materials, products, or equipment are available only in inch-pound units, SI units are omitted.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
12、 user of this standard to establish appropriate safety and health practices and determine the applicability of regulatorylimitations prior to use.1 This test method is under the jurisdiction ofASTM Committee D02 on Petroleum Products, Liquid Fuels, and Lubricants and is the direct responsibility of
13、SubcommitteeD02.B0.03 on Automotive Gear Lubricants or when shifting from low range to high range, for the countershaft 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
14、.2.7 unsynchronized shift, na shift in which the speed of the mating 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 disassembled and all parts, including the case and the oil-circulating a
15、nd heatingsystems, are thoroughly cleaned. The transmission is rebuilt with a new synchronizer assembly, including 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
16、 system are flushed with the test oil in accordance with the flush procedure.4.4 The flush oil is drained, and the 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 transmi
17、ssion is automatically cycled between low and high range until two unsynchronized shifts occur or the desiredlength 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 visu
18、ally 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 manual transmission fluids for thermal instability, which results indeterioration of synchronizer performance.5.2 This test method may a
19、lso be utilized in other specifications and classifications of transmission and gear lubricants such asthe 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 Manual Transmission Lubricants, and5.2.4 Mack Truck GO-H Gear
20、Lubricant Specification.6. Apparatus6.1 Table 1 is a list of the make and model of recommended instruments and equipment.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
21、testing, as listed in Table 2. The main box shift rail cover canbe replaced with an aluminum plate to facilitate 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 te
22、mperature of 250 6 5F (121 C 6 2.7 C)and maintains this temperature throughout the duration of the test. The power 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 Wcm2). The oil flow rate is between 6 and 10 gal/min (23 Lmin to38 L/min). A l
23、ayout of the oil-circulation system is shown in Fig. 3. A detailed drawing of the recommended oil heating chamberis 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
24、 small, increase by lengthening oil hoses. When the system capacity is too great,decrease by shortening hoses, 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 complet
25、ely when draining the system.D5579 1546.5 Oil Return HoleDrill and tap a hole in the compound case for the oil to return after flowing through the heat exchanger.The location and size of this hole are shown in Fig. 5.6.6 Air Pressure ControlsThe transmission is shifted by air pressure applied to alt
26、ernating sides of the range shift piston. Theair pressure is provided by a pilot valve, which is cycled by a solenoid 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 s
27、hown inFig. 6.6.7 Drive SystemIn the truck operation, opposing torques help the synchronizer to complete the shift. 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
28、 can be delayed. To help the synchronizer shift smoothly without the opposing torque, a vibration inthe drive 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 out
29、put shaft is offset from the shaft of the motor or jack shaft,thereby placing the driveline at an angle. A layout 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 comput
30、er, 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 shifting), and6.8.6 Coast down time.6.9 Thermocouple PlacementTransmission sump temperature is measured in the compound section of the transmission
31、 witha thermocouple and conventional display equipment. Drill and tap the compound case to accept the thermocouple 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) i
32、nto the sump. As a means of ensuring that the oil is not exposed to excessive heatin the heater, place an additional thermocouple to measure the oil temperature leaving the heater as shown in Fig. 7.TABLE 1 Recommended Test Stand ComponentsItem Manufacturer Part No.Panel MetersTailshaft rpm Newport
33、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 timer Omron H5BR-B-AC100-240T/C selector switch The
34、rmo 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 pressure switch Penn P61AG-1RelaysAC Potter forkwear; ma
35、nual transmission lubricants; shifting synchronization; shift time; thermal stability;total cycle timeANNEXES(Mandatory Information)A1. ASTM TEST MONITORING CENTER ORGANIZATIONA1.1 Nature and Functions of the ASTM Test Monitoring Center (TMC)The TMC is a non profit organization located inPittsburgh,
36、 Pennsylvania and is staffed to: administer engineering studies; conduct laboratory inspections; perform statisticalanalyses of reference oil test data; blend, store, and ship reference oils; and provide the associated administrative functions tomaintain the referencing calibration program for vario
37、us lubricant tests as directed byASTM Subcommittee D02.B0 and theASTMExecutive Committee. The TMC coordinates its activities with the test sponsors, the test developers, the surveillance panels, andthe testing laboratories. Contact TMC through the TMC Director at:ASTM Test Monitoring Center6555 Penn
38、 AvenuePittsburgh, PA 152064489www.astmtmc.cmu.eduA1.2 Rules of Operation of the ASTM TMCThe TMC operates in accordance with the ASTM Charter, the ASTM Bylaws, theRegulations Governing ASTM Technical Committees, the Bylaws Governing ASTM Committee D02, and the Rules andRegulations Governing the ASTM
39、 Test Monitoring System.A1.3 Management of the ASTM TMCThe management of the Test Monitoring System is vested in the Executive Committeeelected by Subcommittee D02.B0. The Executive Committee selects the TMC Director who is responsible for directing theactivities of the TMC.A1.4 Operating Income of
40、the ASTM TMCThe TMC operating income is obtained from fees levied on the reference oilssupplied and on the calibration tests conducted. Fee schedules are established by the Executive Committee and reviewed bySubcommittee D02.B0.A2. ASTM TEST MONITORING CENTER: CALIBRATION PROCEDURESA2.1 Reference Oi
41、lsThese oils are formulated or selected to represent specific chemical, or performance levels, or both. Theyare usually supplied directly to a testing laboratory under code numbers to ensure that the laboratory is not influenced by priorknowledge of acceptable results in assessing test results. The
42、TMC determines the specific reference oil the laboratory shall test.A2.1.1 Reference Oil Data ReportingTest laboratories that receive reference oils for stand calibration shall submit data to theTMC on every sample of reference oil they receive. If a shipment contains any missing or damaged samples,
43、 the laboratory shallnotify the TMC immediately.A2.2 Calibration Testing:D5579 1515A2.2.1 Full scale calibration testing shall be conducted at regular intervals. These full scale tests are conducted using codedreference oils supplied by the TMC. It is a laboratorys responsibility to keep the onsite
44、reference oil inventory at or above theminimum level specified by the TMC test engineers.A2.2.2 Test Stands Used for Non Standard TestsIf a non standard test is conducted on a previously calibrated test stand, thelaboratory shall conduct a reference oil test on that stand to demonstrate that it cont
45、inues to be calibrated, prior to running standardtests.A2.3 Reference Oil StorageStore reference oils under cover in locations where the ambient temperature is between 10 C and+50 C.A2.4 Analysis of Reference OilUnless specifically authorized by the TMC, do not analyze TMC reference oils, either phy
46、sicallyor chemically. Do not resell ASTM reference oils or supply them to other laboratories without the approval of the TMC. Thereference oils are supplied only for the intended purpose of obtaining calibration under the ASTM Test Monitoring System. Anyunauthorized use is strictly forbidden. The te
47、sting laboratory tacitly agrees to use the TMC reference oils exclusively in accordancewith the TMCs published Policies for Use and Analysis of ASTM Reference Oils, and to run and report the reference oil testresults according to TMC guidelines. Additional policies for the use and analysis of ASTM R
48、eference Oils are available from theTMC.A2.5 Conducting a Reference Oil TestWhen laboratory personnel are ready to run a reference calibration test, they shall requestan oil code via the TMC website.A2.6 Reporting Reference Oil Test ResultsUpon completion of the reference oil test, the test laborato
49、ry transmits the dataelectronically to the TMC, as described in 13.1.3. The TMC reviews the data and contacts the laboratory engineer to report thelaboratorys calibration status. All reference oil test results, whether aborted, invalidated, or successfully completed, shall bereported to the TMCA2.6.1 All deviations from the specified test method shall be reported.A3. ASTM TEST MONITORING CENTER: MAINTENANCE ACTIVITIESA3.1 Special Reference Oil TestsTo ensure continuous severity and precision monitoring, calibration tests are conductedperiodically
