1、Designation: D5579 16Standard 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.INTRODUCTIONThis test method is written for use by laboratories that use the portions of the test metho
3、d that referto ASTM Test Monitoring Center (TMC) services (see Annex A1 Annex A4). Laboratories thatchoose not to use the 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
4、 are 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 testregist
5、ration 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
6、services 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 obtain
7、ed in a test standparticipating in the ASTM TMC services process.1. Scope*1.1 This test method covers the thermal stability of fluids foruse in heavy duty manual transmissions when operated at hightemperatures.1.2 The lubricant performance is measured by the numberof shifting cycles that can be perf
8、ormed without failure ofsynchronization when the transmission is operated while con-tinuously cycling between high and low range.1.3 Correlation of test results with truck transmission ser-vice has not been established. However, the procedure has beenshown to appropriately separate two transmission
9、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 torefinements in the procedure, obsolescence of parts, orreagents, and so forth. These changes will be incorporated byInformation Lett
10、ers 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 units are to be regardedas standard. The values given in parentheses are mathematicalconversions to SI units that are provided for
11、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 This standard does not purport to address all of thesafety concerns, if any, associated with its use. It is theresponsibility of the u
12、ser 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 is arranged as follows:1This test method is under the jurisdiction of ASTM Committee D02 onPetroleum Products, Liquid Fuels, and Lub
13、ricants and is the direct responsibility ofSubcommittee D02.B0.03 on Automotive Gear Lubricants or whenshifting from low range to high range, for the countershaftspeed to decrease from 1700 r min to 500 r min.3.2.6 synchronizer, na pack of friction and reaction platesused to match the speeds of the
14、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 the synchronizer.4. Summary of Test Method4.1 Prior to each test run, the transmission is disassembledand all parts
15、, including the case and the oil-circulating andheating 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
16、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 andcharged to the transmission.4.5 The transmission is started and operated in low rangeuntil the oil temperature reaches
17、 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 failure. The timerequired to shift from high range to low range is recorded eachhour.4.7 At the conclusion of the tes
18、t, the test parts are removedand visually inspected. The shifter fork and friction plates aremeasured again to determine wear.3For referenced ASTM standards, visit the ASTM website, www.astm.org, orcontact ASTM Customer Service at serviceastm.org. For Annual Book of ASTMStandards volume information,
19、 refer to the standards Document Summary page onthe ASTM website.4Available from SAE International (SAE), 400 Commonwealth Dr., Warrendale,PA 15096, http:/www.sae.org.5Available from Standardization Documents Order Desk, DODSSP, Bldg. 4,Section D, 700 Robbins Ave., Philadelphia, PA 19111-5098.6Avail
20、able from Volvo Powertrain, North America, 13302 Pennsylvania Ave.,Hagerstown, MD 21742.D5579 1625. 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 metho
21、d may also be utilized 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-
22、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 test transmission is a MACKT2180, configuration 11KBA51431 (see Fig. 1). Some parts inthe transmission are to be removed and some are to be addedbef
23、ore 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.6.3 Transmission MountsThe transmission is mounted asshown in Fig. 2.6.4 Oil-Circulating SystemThe system heats the oil to thespecified operating t
24、emperature of 250 F 6 5 F (121 C 62.7 C) and maintains this temperature throughout the durationof the test. The power density of the heater is not high enoughto cause degradation of the oil (22 W/in.2to 25 W/in.2(3.4 W cm2to 3.9 W cm2). The oil flow rate is between6 gal min and 10 gal/min (23 L min
25、to 38 L/min). A layout ofthe oil-circulation system is shown in Fig. 3. A detaileddrawing of the recommended oil heating chamber is shown inFig. 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 c
26、apacity is too small,increase by lengthening oil hoses. When the system capacity istoo great, decrease by shortening hoses, if it is practical to doso; otherwise, install an inert (stainless steel) block in thetransmission main box sump to raise the oil level. Route the oillines so that they will em
27、pty completely when draining thesystem.6.5 Oil Return HoleDrill and tap a hole in the compoundcase for the oil to return after flowing through 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 alter
28、nating 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-shiftdata for the pass/fail criteria of the test. A typical air controlsystem is shown
29、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 loading on the input pinion. The torques,therefore, are not present, and shifting can b
30、e 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 respect to the other by a one spline tooth offset (22). Thetransmission output shaft
31、 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 InstrumentationSupply sensors and displays, either onthe test console or in a data logging computer, as follow
32、s: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 tem-perature is measured in the compound section of the transmis-sion with a the
33、rmocouple 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 wall of the main case.Position the tip of the thermocouple to extend 1.5 in. (38 mm)into the sump.
34、 As a means of ensuring that the oil is notTABLE 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 IndicationTemperature controller Omron E
35、SEX-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 RO-8-300 RNMAShift solenoid Asco
36、 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 Information)A1. ASTM TEST MONITORIN
37、G CENTER ORGANIZATIONA1.1 Nature and Functions of the ASTM Test MonitoringCenter (TMC)The TMC is a non profit organizationlocated in Pittsburgh, Pennsylvania and is staffed to: administerengineering studies; conduct laboratory inspections; performstatistical analyses of reference oil test data; blen
38、d, store, andship reference oils; and provide the associated administrativefunctions to maintain the referencing calibration program forvarious lubricant tests as directed by ASTM SubcommitteeD02.B0 and the ASTM Executive Committee. The TMCcoordinates its activities with the test sponsors, the testd
39、evelopers, the surveillance panels, and the testing laborato-ries. Contact TMC through the TMC Director at:ASTM Test Monitoring Center6555 Penn AvenuePittsburgh, PA 152064489www.astmtmc.cmu.eduA1.2 Rules of Operation of the ASTM TMCThe TMCoperates in accordance with the ASTM Charter, the ASTMBylaws,
40、 the Regulations Governing ASTM TechnicalCommittees, the Bylaws Governing ASTM Committee D02,and the Rules and Regulations Governing the ASTM TestMonitoring System.A1.3 Management of the ASTM TMCThe management ofthe Test Monitoring System is vested in the Executive Com-mittee elected by Subcommittee
41、 D02.B0. The Executive Com-mittee selects the TMC Director who is responsible fordirecting the activities of the TMC.A1.4 Operating Income of the ASTM TMCThe TMCoperating income is obtained from fees levied on the referenceoils supplied and on the calibration tests conducted. Feeschedules are establ
42、ished by the Executive Committee andreviewed by Subcommittee D02.B0.TABLE 5 Reference Oil PrecisionAVariable Intermediate Precision ReproducibilitySi.p.Bi.p.CSRBRCCycles to Fail 9131 25567 9131 25567AThese statistics are based on results obtained on TMC Reference Oils 151-2 and151-3 with Configurati
43、on 2 hardware over the period from Jan. 25, 1999 throughMarch 19, 2005.BS = standard deviation.CThis value is obtained by multiplying the standard deviation by 2.8.D5579 1610A2. ASTM TEST MONITORING CENTER: CALIBRATION PROCEDURESA2.1 Reference OilsThese oils are formulated or selectedto represent sp
44、ecific chemical, or performance levels, or both.They are usually supplied directly to a testing laboratory undercode numbers to ensure that the laboratory is not influenced byprior knowledge of acceptable results in assessing test results.The TMC determines the specific reference oil the laboratorys
45、hall test.A2.1.1 Reference Oil Data ReportingTest laboratoriesthat receive reference oils for stand calibration shall submitdata to the TMC on every sample of reference oil they receive.If a shipment contains any missing or damaged samples, thelaboratory shall notify the TMC immediately.A2.2 Calibra
46、tion Testing:A2.2.1 Full scale calibration testing shall be conducted atregular intervals. These full scale tests are conducted usingcoded reference oils supplied by the TMC. It is a laboratorysresponsibility to keep the onsite reference oil inventory at orabove the minimum level specified by the TM
47、C test engineers.A2.2.2 Test Stands Used for Non Standard TestsIf a nonstandard test is conducted on a previously calibrated test stand,the laboratory shall conduct a reference oil test on that stand todemonstrate that it continues to be calibrated, prior to runningstandard tests.A2.3 Reference Oil
48、StorageStore reference oils undercover in locations where the ambient temperature is between10 C and +50 C.A2.4 Analysis of Reference OilUnless specifically autho-rized by the TMC, do not analyze TMC reference oils, eitherphysically or chemically. Do not resell ASTM reference oils orsupply them to o
49、ther laboratories without the approval of theTMC. The reference oils are supplied only for the intendedpurpose of obtaining calibration under the ASTM Test Moni-toring System. Any unauthorized use is strictly forbidden. Thetesting laboratory tacitly agrees to use the TMC reference oilsexclusively in accordance with the TMCs published Policiesfor Use and Analysis of ASTM Reference Oils, and to run andreport the reference oil test results according to TMC guide-lines. Additional policies for the use and analysis of ASTMReference Oils are availa
