1、 FORD LABORATORY TEST METHOD BJ 012-01 Date Action Revisions 2001 07 24 Revised Editorial no technical change A. Cockman 1992 05 08 Printed copies are uncontrolled Page 1 of 19 Copyright 2001, Ford Global Technologies, Inc. MERC-O-MATIC TRANSMISSION FLUID OXIDATION BENCH TEST Application This proced
2、ure is used to determine the high temperature oxidation stability of automatic transmission fluids and any other similar fluids. Summary of Test Method This method consists of constant speed operation of an automatic transmission for a prescribed time at a specified temperature with air passing thro
3、ugh the fluid. As measures of oxidation, changes in the properties of the fluid are determined and deposits in the transmission are rated at the end of the test. Apparatus Required Transmission A new current model three speed automatic transmission shall be used for each test. Source: Transmission D
4、ivision Sales the transmission is removed from the stand and the converter is drained. The transmission is then remounted on the stand. Test Procedure 1. Introduce 4.7 L of the fluid to be tested into the transmission at approximately 105 rad/s. 2. Shut down and introduce another 4.7 L of fluid. 3.
5、Shift transmission into the drive position. 4. Start motor and operate at 225 rad/s bringing transmission to the test temperature within 4 h. Adjust the T-V adaptor fitting to maintain a transmission pressure of 550 +/- 30 Pa. 5. After the unit reaches the test temperature, open and adjust the air b
6、leed valve to draw air into the transmission at a rate of 200 +/- 4 mL per minute at a temperature and pressure of 20 C and 101 kPa. This air flow is to be maintained except during warm-up and the air is to be drawn in from outside the insulated box. FORD LABORATORY TEST METHOD BJ 012-01 Page 6 of 1
7、9 Copyright 2001, Ford Global Technologies, Inc. 6. Continue to operate 24 h per day at the speed and temperature until 300 h are logged. At 100 and 200 h withdraw a 2 ounce sample and shut down the test allowing the transmission to cool to 23 +/- 2 C. Tests must be scheduled by laboratories on a no
8、rmal five day schedule, so that scheduled shut downs coincide with normal weekend shut downs. If upon completion of 300 test hours, less than 288 hours are logged at the required temperature, continue the run beyond the 300 hours until 288 hours at the test temperature have been completed. 7. Termin
9、ate test if total oil loss for a test including sample should exceed 300 mL. No new fluid may be added during the test. 8. Air out of the transmission should be checked periodically at the transmission vent. This may be done with a soap film flowmeter of the type illustrated in Figure 5. Air out of
10、the transmission should generally be between 170 and 190 mL/minute corrected to 20 C and 101 kPa. If the air out is greater than 190 mL/minute then transmission setup should be examined for leaks. If less than 170 mL/minute, the air bleed system should be checked for leaks, restrictions, flowmeter c
11、alibration, etc. The air out of the transmission should be checked daily. Note: Instruments used in the test should be calibrated frequently enough to insure that test conditions are met within the test tolerance. Inspection Procedure 1. Running Inspection: Take small samples of fluid every 25 hours
12、 and place 1 - 2 drops on a blotter pad. The color of the stain provides a subjective means of following the oxidation of the oil. 2. Take 60 mL samples of fluid each 100 hours. 3. After completion of 300 hours, or 288 hours time at the required temperature, whichever is longer, shut down and disass
13、emble the transmission; cut the converter open around the weld and inspect thoroughly. 4. Rate the individual components according to the Coordinating Research Council Deposit Rating Scale (CRC Manual 9) for varnish and Area Depth Method (CRC Manual 10) for sludge. Ten represents a perfectly clean p
14、art. FORD LABORATORY TEST METHOD BJ 012-01 Page 7 of 19 Copyright 2001, Ford Global Technologies, Inc. Rating Procedure The following data shall be recorded on the standard Merc-O-Matic Test Data form (Figure 7). 1. Inspect all transmission parts for sludge and varnish after the test. Specifically i
15、nspect and rate according to the CRC Varnish and Sludge Rating System the following parts: Part Name Varnish Sludge Turbine Outer Surface X Converter Housing, Sludge Ring X Screen, Oil X X Steel Clutch Plates X Valve Body - Outer Surface X Valve Body - Separator Plate X Valve Body Spools X Valve Bod
16、y Cavities X X Clutch Pistons X Clutch Cylinders X Sun Gear Shaft X Bottom of Transmission X 2. Record the condition of the following: Oil Seals: Cracking, flexibility, etc. when bent 180 deg. Silicone Seal: Reversion Brass Washers: Corrosion, wear, discoloration Bearings: Wear, corrosion, metal tra
17、nsfer Nylon Gear (if used): General condition of teeth, etc. 3. Report the properties of used fluid samples as follows: (a) Weight pentane insolubles: Millipore Method (0.45 micrometre) (b) Viscosity at 100 and 210 F ASTM D 445 (c) Acid Number ASTM D 664 (e) Infrared Absorbance change at 0.10 mm fix
18、ed cell 5.8 - 5.9 microns 4. Photograph in color, the transmission parts rated and summed for the purpose of determining the overall visual condition of the transmission and any other items that may be of interest. Layout for the photographs shall be in accord with Figure 8, 9 and 10. FORD LABORATOR
19、Y TEST METHOD BJ 012-01 Page 8 of 19 Copyright 2001, Ford Global Technologies, Inc. Evaluation of Results The following items shall be rated and summed for the purpose of determining the overall condition of the transmission: Part Name Varnish Sludge Turbine Outer Surface X Converter Housing Sludge
20、Ring X Screen X X Steel Clutch Plates X Valve Body - Outer Surface X Valve Body Cavities X Clutch Pistons X Clutch Cylinder X Bottom of Transmission X Totals XX XX A perfectly clean transmission would rate 50 varnish and 50 sludge for a total of 100. Repeatability and reproducibility of this test pr
21、ocedure are dependent upon the following factors: 1. Preparation of transmission for test 2. Shut-down periods 3. Maintaining satisfactory temperature control 4. Air intake or leakage 5. Number of hours at test conditions Chemicals, materials, parts, and equipment referenced in this document must be
22、 used and handled properly. Each party is responsible for determining proper use and handling in its facilities. FORD LABORATORY TEST METHOD BJ 012-01 Page 9 of 19 Copyright 2001, Ford Global Technologies, Inc. MERC-O-MATIC TRANSMISSION OXIDATION BENCH TEST Figure 1 FORD LABORATORY TEST METHOD BJ 01
23、2-01 Page 10 of 19 Copyright 2001, Ford Global Technologies, Inc. Figure 2 FORD LABORATORY TEST METHOD BJ 012-01 Page 11 of 19 Copyright 2001, Ford Global Technologies, Inc. Figure 3 FORD LABORATORY TEST METHOD BJ 012-01 Page 12 of 19 Copyright 2001, Ford Global Technologies, Inc. MERC-O-MATIC TRANS
24、MISSION OXIDATION BENCH TEST Note: Dimensions are not absolute, but have been determined acceptable in testing. A. Location of Petcock and Sight Glass B. Location of Angle Thermometer C. Location of Sump Thermocouple Converter outlet thermocouple is located in the outlet hole nearest the converter f
25、or the cooler tube in the transmission case. Figure 4 FORD LABORATORY TEST METHOD BJ 012-01 Page 13 of 19 Copyright 2001, Ford Global Technologies, Inc. MERC-O-MATIC TRANSMISSION OXIDATION BENCH TEST Soap bubble air-flow meter: The separatory funnel is raised to coat the sides of the burette with th
26、e soap solution and then lowered so that the liquid level is below the side inlet, leaving a small amount of soap in the side inlet. The transmission vent is connected to side inlet and the air out of the transmission is checked by measuring the time for the bubble formed to travel 50 milliliters up
27、 the burette. Figure 5 FORD LABORATORY TEST METHOD BJ 012-01 Page 14 of 19 Copyright 2001, Ford Global Technologies, Inc. MERC-O-MATIC TRANSMISSION OXIDATION BENCH TEST Adjusting Bolt Replacing the Vacuum Diaphragm for the T-V Linkage Figure 6 FORD LABORATORY TEST METHOD BJ 012-01 Page 15 of 19 Copy
28、right 2001, Ford Global Technologies, Inc. MERC-O-MATIC TEST DATA Test Date: Test No: Fluid: Test Time at Temp: Test Temp: Airflow: Trans. No. Trans. Type: Converter Type: Transmission Rating Part Description Varnish Sludge Turbine - Outer Surface X Turbine Housing - Sludge Ring X Turbine Screen X X
29、 Steel Clutch Plates X Valve Body - Outer Surface X Valve Body - Separation Plate Valve Body - Spools Valve Body Cavities X Bottom of Transmission - Whole Area X Clutch Pistons X Sun Gear Shaft Clutch Cylinder X TOTALS RATING Used in Totals Rating Bronze Washers Br. Th. W. Rat. Oil Seals % Viscosity
30、 Increase At 100 F At 210 F Bearings Oil Data Test Hours Original 100 200 300 Pentane Insolubles Wt. % Viscosity at 100 F, cSt Viscosity at 210 F, cSt Strong Acid Number, mg KOH/g Total Acid Number, mg KOH/g Absorptivity (5.8 - 5.9) cm-1 Absorptivity After Centrifuging cm-1 Figure 7 FORD LABORATORY
31、TEST METHOD BJ 012-01 Page 16 of 19 Copyright 2001, Ford Global Technologies, Inc. MERC-O-MATIC TEST DATA Arrangement of Transmission Components Rated and Summed for Sludge Figure 8 FORD LABORATORY TEST METHOD BJ 012-01 Page 17 of 19 Copyright 2001, Ford Global Technologies, Inc. MERC-O-MATIC TEST D
32、ATA Arrangement of Transmission Components Rated and Summed for Varnish Figure 9 FORD LABORATORY TEST METHOD BJ 012-01 Page 18 of 19 Copyright 2001, Ford Global Technologies, Inc. MERC-O-MATIC TEST DATA Example of transmission components included in report because of special interest. The above pict
33、ure was included due to excessive sludge deposits. Figure 10 FORD LABORATORY TEST METHOD BJ 012-01 Page 19 of 19 Copyright 2001, Ford Global Technologies, Inc. Ford Motor Company Fuel Sciences Department Scientific Research Staff P.O. Box 2053 Dearborn, Michigan 48121 Request for Revision Information On Merc-O-Matic Test Procedure NAME COMPANY ADDRESS Now running procedure Yes No
