ASTM D5579-2009a Standard Test Method for Evaluating the Thermal Stability of Manual Transmission Lubricants in a Cyclic Durability Test.pdf

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1、Designation: D5579 09aStandard 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 ca

2、se 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. Scope1.1 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, or re-agents, 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-pou

6、nd 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

7、This 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 metho

8、d 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 Placeme

9、nt 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

10、 and 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 A1Test Kit Parts Ann

11、ex A2HTCT Test Report Forms and Data Dictionary Annex A3Manual Transmission Cyclic Durability Test PartsInspection and Wear MeasurementsAnnex A42. Referenced Documents2.1 ASTM Standards:3D235 Specification for Mineral Spirits (Petroleum Spirits)(Hydrocarbon Dry Cleaning Solvent)E29 Practice for Usin

12、g Significant Digits in Test Data toDetermine Conformance with Specifications1This test method is under the jurisdiction of ASTM Committee D02 onPetroleum Products and Lubricants and is the direct responsibility of SubcommitteeD02.B0.03 on Automotive Gear Lubricants otherwise, install an inert (stai

13、nlesssteel) block in the transmission main box sump to raise the oillevel. Route the oil lines so that they will empty completelywhen draining the system.6.5 Oil Return HoleA hole shall be drilled and tapped inthe compound case for the oil to return after flowing throughthe heat exchanger. The locat

14、ion and size of this hole are shownin Fig. 5.NOTE 1Left side view.NOTE 2See Table 2 for references to letters in brackets.FIG. 1 Transmission Modified for TestingTABLE 2 Transmission Parts to Be Added or Removed BeforeTestingNOTELetters in brackets, , refer to locations indicated on Fig. 1.Parts to

15、Be RemovedRails, forks, springs, and ball from the mainbox shift cover AAll main box gesting B:Mainshaft gears and thrust washersCountershaft assembliesSliding clutches (320KB3136, (2)320KB3137A)Compound CSplitter clutch (320KB3141)Splitter piston and fork (336KC333, 575KB3378)Bell Housing DAll clut

16、ch related partsShafts (604KC277A, 604KC34B)Yoke (301KD43B)Parts to Be AddedSpeedometer plug (37KC12) and washer (37AX419)Pipe extension,18 NPT and orifice (63AX3466) to Range ValveReplace cast iron piston housing cover with fabricated steel cover ED5579 09a36.6 Air Pressure ControlsThe transmission

17、 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. These cycles arerecorded by a counter, which provides the cycles to mis-shiftdata for the pass/fail criteria of the

18、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 transmission is driven from the rear by an electric motorand belt drive with no loading on the input pinion. The torques,the

19、refore, 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 drivelineis set out of phase by rotating the yoke at one end of the shaftwith respect to the other by a one spline toot

20、h 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 relative to the jack shaftis shown in Fig. 2.6.8 InstrumentationSensors and displays, either on thetest console or i

21、n a data logging computer, are to be suppliedas 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 tem-perature is measured i

22、n 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 centerline of the transmission8.0 in. (203 mm) forward of the back wall of the main case.Position the tip of th

23、e thermocouple to extend 1.5 in. (38 mm)into the sump. As a means of ensuring that the oil is notFIG. 2 Typical Layout of Drive SystemFIG. 3 Schematic of Oil SystemD5579 09a4exposed to excessive heat in the heater, place an additionalthermocouple to measure the oil temperature leaving the heateras s

24、hown 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 C for AromaticContent (0-2%

25、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 procedures and equip-ment that may a

26、ssist in reducing safety hazards. No attempt hasbeen made to address all possible safety problems. The user ofNOTE 1Material 1018 is similar material.NOTE 2All dimensions are in inches, unless otherwise noted.FIG. 4 Typical Oil Heater ChamberNOTEFigure is not drawn to scale.FIG. 5 Oil Return Hole Lo

27、cationFIG. 6 Air Control and Supply SystemFIG. 7 Location of Oil Out-of-Heater Thermocouple, PressureRegulator, and SensorD5579 09a5this test method is responsible for establishing appropriatesafety and health practices.8.2 The operating of transmission tests can expose person-nel and facilities to

28、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 approved by

29、 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 operatin

30、g, 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 or flowi

31、ng 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 free of

32、 alltripping hazards. In case of injury, no matter how slight, firstaid attention should be applied at once and the incidentreported. Personnel should be alert for leaking oil, whichrepresents a fire hazard. Containers of oil cannot be permittedto accumulate in the test area.8.5 A remote station for

33、 shutting off the motor, pump, andheater is recommended. Fixed fire-protection equipmentshould be provided.8.6 Normal precautions should be taken when using flam-mable solvents for cleaning purposes. Make sure adequateventilation is provided and fire-fighting equipment is immedi-ately accessible.8.7

34、 It is recommended that safeties be provided to shutdown the drive motor and oil heater when the followingconditions occur:8.7.1 Oil temperature in transmission sump becomes exces-sive,8.7.2 Oil temperature leaving the oil-heating chamber be-comes excessive,8.7.3 Oil-circulating system loses pressur

35、e,8.7.4 Motor over-speeds or under-speeds, and8.7.5 The fire-protection system is activated.8.8 See Fig. 8 for a typical schematic of safety circuits.9. Preparation of Apparatus9.1 Cleaning of Parts:9.1.1 Transmission CaseThoroughly clean the transmis-sion case with a cleaning solvent (see 7.2) to r

36、emove any oil,sludge, or varnish deposits remaining from the previous testand then air dry.9.1.2 Gears, Shafts, SynchronizerRemove all sludge, var-nish, and deposits. Rinse with a cleaning solvent (see 7.2) andair dry.9.1.3 Heater, Oil-Circulating SystemFlush oil lines with acleaning solvent (see 7.

37、2) to remove any previous test oil andthen air dry. Disassemble the heater, clean, and air dry aftereach test. Check the heater periodically for leaks and replacewhen necessary.9.2 Assembly:FIG. 8 Typical Schematics of Safety CircuitsTABLE 3 Part Numbers for Approved ConfigurationsTest Hardware Conf

38、igurationPart description Configuration 1 Configuration 2Synchronizer clutch assembly 320KB450C 320KB459ASynchronizer pin (3 each) 301KC240B 301KC33Synchronizer pin (3 each) 301KC241B 301KC34Synchronizer pin (3 each) 48AX17 301KC35Synchronizer pre-load spring (3 each) 107KD244 107KD247High range mai

39、nshaft gear 751KB489 751KB4123Low range mainshaft hub 84KC42 84KC47Compound mainshaft, rear 601KC429 601KC432Bearing, compound mainshaft None required 46AX538Thrust washers, mainshaft (2 each) 223KD316A None requiredSnap ring (2 each) 97AX151 or97AX17197AX151 or97AX171Snap ring (2 each) 97AX267 97AX

40、267Shift rail 591KC3154A 591KC3154AO-ring, low range shift piston 56AX560 56AX560Piston, high low range shiftA336KC318 336KC318Cylinder housing, hi-lo shift piston 55KC46A 55KC46AO-ring, compound shift piston None required None requiredO-ring, range high low shift piston 56AX588 56AX588Countershaft

41、gear, front 757KB3322757KB4108757KB3322757KB4108Countershaft gear, rear 757KB4106757KB440A757KB4106Range shift valve 216KD123 216KD42AThe piston, high low range shift, has an outside diameter of 3.740 to 3.738 in.(95.00 to 94.95 mm).D5579 09a69.2.1 GeneralAssemble all parts as instructed in theMack

42、Transmission Service Manual T2130/2180,6exceptwhere the service manual applies to parts that are modified forthis test method. Use the part numbers identified in Table 3 forthe appropriate hardware configuration. Use test oil for lubri-cating parts during assembly. For all tests (reference andnon-re

43、ference oil) starting after June 9, 1999, use only hard-ware listed under Configurations 1 or 2 in Table 3.9.2.2 New PartsObtain the following parts from an au-thorized Mack truck dealer. Install the following new parts foreach test:NumberRequiredMackPart No.Kit (Parts in this kit are listed in Anne

44、x A2) 1 377SH21Friction Plate 8 N/A7Range Fork 1 575KB457Low Range Mainshaft Hab 1 84KC47(Configuration 2only)9.2.2.1 Inspect the following parts after each test andreplace if worn or damaged:Number Required Mack Part No.Thrust Washer 3 223KD249Thrust Washer 2 223KD316AClutch Housing 2 53KC486CHigh

45、Range Mainshaft Gear 1 751kB4123(Configuration 2only)9.2.3 Inspection of Air ValvesInspect the piston of therange shift valve and the fork air cylinder and replace ifdamaged or visibly worn. Replace the O-rings in these valveswhen nicked, cut, softened, or hardened. However, replacethese O-rings at

46、least every six months. Install a116-in. thickshim between the shaft cylinder and the transmission case forConfiguration 2 tests.9.2.4 Pre-test MeasurementsMeasure the range fork forhardness and thickness at the locations shown in Fig.A4.1. Thehardness of the fork pads shall be a minimum of 55 Rcat

47、eachof the four locations. Mark the friction disks on the spline tangswith an etching tool at three locations equally spaced. Measureand record the pad thickness at these locations in the DataDictionary (see Annex A3).9.2.4.1 This hardness is greater than the manufacturingminimum. Some parts meeting

48、 the manufacturing specificationmay be rejected for this test method.9.2.5 Countershaft Bearing PreloadMeasure the pre-loadon each of the three countershafts prior to each test as follows:9.2.5.1 Assemble the transmission as specified in the MackTransmission Service Manual up to and including instal

49、ling theyoke on the output shaft. Rotate the transmission so that theshafts are vertical.9.2.5.2 Remove the bearing cap from the rear cover for thefirst countershaft to be checked. Measure the thickness of a0.010-in. (0.254 mm) nominal shim, and record. Add the shimto the shim pack of the shaft, and reinstall the bearing cap.Torque the bolts to 40 to 50 lb-ft (54 Nm to 68 Nm).9.2.5.3 Mount a dial indicator in the main transmission case,and adjust the indicator probe to measure the axial end play ofthe countershaft.9.2.5.4 Using a pry bar, m