Evaluating The Thermal Stability of Manual Transmission Lubricants in A Cyclic Durability Test
Evaluating The Thermal Stability of Manual Transmission Lubricants in A Cyclic Durability Test
Evaluating The Thermal Stability of Manual Transmission Lubricants in A Cyclic Durability Test
INTRODUCTION
This test method is written for use by laboratories that use the portions of the test method that refer
to ASTM Test Monitoring Center (TMC) services (see Annex A1 – Annex A4). Laboratories that
choose not to use the TMC services may simply disregard these portions.
The TMC provides reference oils, and engineering and statistical services to laboratories that desire
to produce test results that are statistically similar to those produced by laboratories previously
calibrated by the TMC.
In general, the Test Purchaser decides if a calibrated test stand is to be used. Organizations such as
the American Chemistry Council require that a laboratory use the TMC services as part of their test
registration process. In addition, the American Petroleum Institute and the Gear Lubricant Review
Committee of the Lubricant Review Institute (SAE International) require that a laboratory use the
TMC services in seeking qualification of oils against their specifications.
NOTE 1—The advantage of using the TMC services to calibrate test stands is that the test laboratory (and hence the
Test Purchaser) has an assurance that the test stand was operating at the proper level of test severity. It should also be
borne in mind that results obtained in a non calibrated test stand may not be the same as those obtained in a test stand
participating in the ASTM TMC services process.
1
This test method is under the jurisdiction of ASTM Committee D02 on
Petroleum Products, Liquid Fuels, and Lubricants and is the direct responsibility of
Subcommittee D02.B0.03 on Automotive Gear Lubricants & Fluids.
Current edition approved April 1, 2016. Published April 2016. Originally
approved in 1994. Last previous edition approved in 2015 as D5579 – 15. DOI:
10.1520/D5579-16.
2
This edition incorporates revisions in all Information Letters through No. 15–1. ASTM Test Monitoring Center, 6555 Penn Ave., Pittsburgh, PA 15206-4489.
1
D5579 − 16
Section 3. Terminology
Scope 1
Referenced Documents 2 3.1 Definitions:
Terminology 3 3.1.1 wear, n—the loss of material from a surface, generally
Summary of Test Method 4
Significance and Use 5
occurring between two surfaces in relative motion, and result-
Apparatus 6 ing from mechanical or chemical action or a combination of
Test Transmission 6.2 both. D7422
Transmission Mounts 6.3
Oil-Circulating System 6.4 3.2 Definitions of Terms Specific to This Standard:
Oil Return Hole 6.5 3.2.1 dual-range transmission, n—a type of transmission in
Air Pressure Controls 6.6
Drive System 6.7 which the driver first shifts through all of the mainbox gear
Instrumentation 6.8 ratios in low range, and then shifts to high range and shifts
Thermocouple Placement 6.9 through the mainbox again. The section containing the high-
Reagents and Materials 7
Safety 8 low range is the compound section.
Preparation of Apparatus 9
Cleaning of Parts 9.1
3.2.2 friction disk, n—a steel circular plate to which a
Assembly 9.2 friction material has been bonded.
Calibration 10
Transmission and Test Stand Calibration 10.1 3.2.3 glazed, adj—the condition of the friction disks when
Reference Oils 10.2 precipitates have filled the pores in the friction material,
Reference Oil Test Frequency 10.3 polishing the surface, and changing the frictional properties.
Instrumentation Calibration 10.4
Shift Time Calibration 10.5 3.2.4 reaction disk, n—a steel disk that mates with the
Operating Procedure 11
System Flush and Charge 11.1
friction disk during synchronization.
Test Operation 11.2 3.2.5 shift time, n—the period of time required, when
Shut-Down Procedure 11.3
Transmission Disassembly 11.4
shifting from high range to low range, for the countershaft
Determination of Test Results 12 speed to increase from 500 r ⁄min to 1700 r ⁄min; or when
Failure Criteria 12.1 shifting from low range to high range, for the countershaft
Shifter Fork Wear 12.2
Test Validity Determination 12.3 speed to decrease from 1700 r ⁄min to 500 r ⁄min.
Report 13 3.2.6 synchronizer, n—a pack of friction and reaction plates
Precision and Bias 14
Keywords 15 used to match the speeds of the low- and high-range gears prior
Test Validity Calculations and Limits Annex A5 to engagement.
HTCT Test Report Forms and Data Dictionary Annex A6
Manual Transmission Cyclic Durability Test Parts Annex A7 3.2.7 unsynchronized shift, n—a shift in which the speed of
Inspection and Wear Measurements the mating gears is not matched to the speed of the transmis-
2. Referenced Documents sion output shaft by the synchronizer.
2.1 ASTM Standards:3 4. Summary of Test Method
D235 Specification for Mineral Spirits (Petroleum Spirits)
(Hydrocarbon Dry Cleaning Solvent) 4.1 Prior to each test run, the transmission is disassembled
D7422 Test Method for Evaluation of Diesel Engine Oils in and all parts, including the case and the oil-circulating and
T-12 Exhaust Gas Recirculation Diesel Engine heating systems, are thoroughly cleaned. The transmission is
E29 Practice for Using Significant Digits in Test Data to rebuilt with a new synchronizer assembly, including measured
Determine Conformance with Specifications shifter fork, friction, and reaction disks. All other worn or
2.2 SAE Standard: defective parts are replaced.
SAE J308 Axle and Manual Transmission Lubricants4 4.2 The rebuilt transmission is installed on a test stand.
2.3 Military Standard:
MIL-L-2105 Lubricating Oil, Gear, Multipurpose5 4.3 The transmission and oil system are flushed with the test
2.4 Other Standard: oil in accordance with the flush procedure.
GO-H Mack Trucks Oil,Gear: Multi-Purpose6 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.
3
For referenced ASTM standards, visit the ASTM website, www.astm.org, or
4.6 The transmission is automatically cycled between low
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM and high range until two unsynchronized shifts occur or the
Standards volume information, refer to the standard’s Document Summary page on desired length of test is reached without failure. The time
the ASTM website. required to shift from high range to low range is recorded each
4
Available from SAE International (SAE), 400 Commonwealth Dr., Warrendale,
PA 15096, http://www.sae.org. hour.
5
Available from Standardization Documents Order Desk, DODSSP, Bldg. 4,
4.7 At the conclusion of the test, the test parts are removed
Section D, 700 Robbins Ave., Philadelphia, PA 19111-5098.
6
Available from Volvo Powertrain, North America, 13302 Pennsylvania Ave., and visually inspected. The shifter fork and friction plates are
Hagerstown, MD 21742. measured again to determine wear.
2
D5579 − 16
5. Significance and Use 2.7 °C) and maintains this temperature throughout the duration
5.1 This test method is used to evaluate automotive manual of the test. The power density of the heater is not high enough
transmission fluids for thermal instability, which results in to cause degradation of the oil (22 W/in.2 to 25 W/in.2
deterioration of synchronizer performance. (3.4 W ⁄cm2 to 3.9 W ⁄cm2)). The oil flow rate is between
6 gal ⁄min and 10 gal/min (23 L ⁄min to 38 L/min). A layout of
5.2 This test method may also be utilized in other specifi- the oil-circulation system is shown in Fig. 3. A detailed
cations and classifications of transmission and gear lubricants drawing of the recommended oil heating chamber is shown in
such as the following: Fig. 4. The total oil capacity of the test system is 5.25 gal
5.2.1 (final API designation of PG-1), (19.87 L) with the oil level in the transmission at the lower
5.2.2 Military Specification MIL-L-2105, edge of the fill hole. If the system capacity is too small,
5.2.3 SAE Information Report J308 Axle and Manual increase by lengthening oil hoses. When the system capacity is
Transmission Lubricants, and too great, decrease by shortening hoses, if it is practical to do
5.2.4 Mack Truck GO-H Gear Lubricant Specification. so; otherwise, install an inert (stainless steel) block in the
transmission main box sump to raise the oil level. Route the oil
6. Apparatus
lines so that they will empty completely when draining the
6.1 Table 1 is a list of the make and model of recommended system.
instruments and equipment.
6.5 Oil Return Hole—Drill and tap a hole in the compound
6.2 Test Transmission—The test transmission is a MACK case for the oil to return after flowing through the heat
T2180, configuration 11KBA51431 (see Fig. 1). Some parts in exchanger. The location and size of this hole are shown in Fig.
the transmission are to be removed and some are to be added 5.
before testing, as listed in Table 2. The main box shift rail
cover can be replaced with an aluminum plate to facilitate 6.6 Air Pressure Controls—The transmission is shifted by
transmission cleaning at end of test. air pressure applied to alternating sides of the range shift
piston. The air pressure is provided by a pilot valve, which is
6.3 Transmission Mounts—The transmission is mounted as cycled by a solenoid valve at a rate of 5 cpm. These cycles are
shown in Fig. 2. recorded by a counter, which provides the cycles to mis-shift
6.4 Oil-Circulating System—The system heats the oil to the data for the pass/fail criteria of the test. A typical air control
specified operating temperature of 250 °F 6 5 °F (121 °C 6 system is shown in Fig. 6.
6.7 Drive System—In the truck operation, opposing torques
TABLE 1 Recommended Test Stand Components help the synchronizer to complete the shift. In the test stand,
Item Manufacturer Part No.
the transmission is driven from the rear by an electric motor
Panel Meters
and belt drive with no loading on the input pinion. The torques,
Tailshaft rpm Newport P-6031D20D therefore, are not present, and shifting can be delayed. To help
Countershaft rpm Newport P-6031D20D the synchronizer shift smoothly without the opposing torque, a
Shift time Newport P-6031D20D
Coast down time Newport P-6031D20D
vibration in the drive line is intentionally excited. The driveline
Control Indication is set out of phase by rotating the yoke at one end of the shaft
Temperature controller Omron ESEX-AF with respect to the other by a one spline tooth offset (22°). The
Temperature indicator Newport INF-0-0-0-0-JF
Cycle counter Redington P2-1006-115AC
transmission output shaft is offset from the shaft of the motor
Cycle timer Omron H5BR-B-AC100-240 or jack shaft, thereby placing the driveline at an angle. A layout
T/C selector switch Thermo Electric 33112 showing the offset of the transmission relative to the jack shaft
Oil psi gage/safety Murphy A-20EO, O-30 psi
Air supply gage U.S. Gage P44U, O-160 psi
is shown in Fig. 2.
Air regulator Norgren RO-8-300 RNMA
Shift solenoid Asco 8317G35, 3-way
6.8 Instrumentation—Supply sensors and displays, either on
solenoid the test console or in a data logging computer, as follows:
Mag. pickup Electro 3010AN 6.8.1 Oil sump temperature,
12 VDC Power supply Sola SLS-12-017
Air pressure switch Penn P61AG-1 6.8.2 Countershaft speed,
Relays—AC Potter & Brumfield KUP14A15 6.8.3 Tail shaft speed,
Relays—DC Potter & Brumfield KUP14D15
Mechanical Components 6.8.4 Air pressure (system),
Air lines Mack 101AX24R, 3⁄8 in. OD 6.8.5 Air pressure (dynamic during shifting), and
Pump Brown & Sharp No. 2
Heater element Chromalox MOT330A, 220v, 1Ph 6.8.6 Coast down time.
Oil lines Aeroquip EC-350, No. 12
U Joint yoke Mack 1710 Series, 6.9 Thermocouple Placement—Transmission sump tem-
38MU3413M perature is measured in the compound section of the transmis-
Drive shaft Rockwell 1710 Series, 52 in. sion with a thermocouple and conventional display equipment.
collapsed
Drive motor General Electric 25-hp Induction Motor, Drill and tap the compound case to accept the thermocouple at
1760 rpm a position located along the centerline of the transmission
High-Speed Recording System 8.0 in. (203 mm) forward of the back wall of the main case.
Pressure transducers Sensotec A-5/1034, 0-100 psi
Oscillograph Astro-Med Dash 4 Position the tip of the thermocouple to extend 1.5 in. (38 mm)
into the sump. As a means of ensuring that the oil is not
3
D5579 − 16
exposed to excessive heat in the heater, place an additional (Warning—Combustible. Health hazard.) Obtain a Certificate
thermocouple to measure the oil temperature leaving the heater of Analysis for each batch of solvent from the supplier.
as shown in Fig. 7.
8. Safety
7. Reagents and Materials 8.1 The following are suggestions of procedures and equip-
7.1 Oil—Approximately 12 gal (45.4 L) of test oil is ment that may assist in reducing safety hazards. No attempt has
required. The integrity of the test oil is the responsibility of the been made to address all possible safety problems. The user of
oil supplier. this test method is responsible for establishing appropriate
7.2 Solvent—Use only mineral spirits meeting the require- safety and health practices.
ments of Specification D235, Type II, Class C for Aromatic 8.2 The operating of transmission tests can expose person-
Content (0-2% vol), Flash Point (142°F/61 °C, min), and Color nel and facilities to a number of safety hazards. Only personnel
(not darker than +25 on Saybolt Scale or 25 on Pt-Co Scale). who are thoroughly trained and experienced in transmission
4
D5579 − 16
5
D5579 − 16
6
D5579 − 16
TABLE 3 Part Numbers for Approved Hardware
Test Hardware Part Numbers
Part description Mack Part Volvo Part
Number Number
A
Synchronizer clutch assembly 320KB459A 25132811A
or or
320KB463B 21636360B
Synchronizer pin (3 each) 301KC33 25500623
Synchronizer pin (3 each) 301KC34 25498886
Synchronizer pin (3 each) 301KC35 25500385
Synchronizer pre-load spring (3 each) 107KD247 25500680
A
High range mainshaft gear 751KB4123 25502562A
or or
751KB4176B 21649207B
A
Low range mainshaft hub 84KC47 25502560A
or or
84KC411B 21631781B
Compound mainshaft, rear 601KC432 ...
Bearing, compound mainshaft 46AX538 25499676
Snap ring (2 each) 97AX151 or 25108495
FIG. 7 Location of Oil Out-of-Heater Thermocouple, Pressure 97AX171
Regulator, and Sensor Snap ring (2 each) 97AX267 ...
Shift rail 591KC3154A ...
O-ring, low range shift piston 56AX560 25108495
Piston, high low range shiftC 336KC318 ...
Cylinder housing, hi-lo shift piston 55KC46A ...
O-ring, range high low shift piston 56AX588 20705679
Countershaft gear, front 757KB3322 or ...
757KB4108
Countershaft gear, rear 757KB4106 ...
Range shift valve 216KD42 21041938
A
Parts required in hardware “CONFIGURATION 2”.
B
Parts required in hardware “CONFIGURATION 3”.
C
The piston, high low range shift, has an outside diameter of 3.740 to 3.738 in.
(95.00 to 94.95 mm).
Number Mack Volvo damaged or visibly worn. Replace the O-rings in these valves
Required Part No. Part No. when nicked, cut, softened, or hardened. However, replace
Thrust Washer 3 223KD249 25500345
Thrust Washer 2 223KD316A 25500919
these O-rings at least every six months. Install a 1⁄16-in.
Clutch Housing 2 53KC486C 25502585 (1.59 mm) thick shim between the shaft cylinder and the
High Range Main Shaft Gear 1 751KB4123A 25502562A transmission case for “CONFIGURATION 2” and “CON-
or or
751KB4176B 21649207B FIGURATION 3” tests.
9.2.4 Pre-test Measurements—Measure the range fork for
A
One of the parts required in hardware “CONFIGURATION 2”. hardness and thickness at the locations shown in Fig. A7.1. The
B
One of the parts required in hardware “CONFIGURATION 3”.
hardness of the fork pads shall be a minimum of 55 Rc at each
9.2.3 Inspection of Air Valves—Inspect the piston of the of the four locations. Mark the friction disks on the spline tangs
range shift valve and the fork air cylinder and replace if with an etching tool at three locations equally spaced. Measure
7
D5579 − 16
and record the pad thickness at these locations in the Data 10. HTCT-specific Calibration and Standardization Items
Dictionary (see Annex A6). (See Annex A2 for general calibration and standardization
9.2.4.1 This hardness is greater than the manufacturing information)
minimum. Some parts meeting the manufacturing specification 10.1 Transmission and Test Stand Calibration—Calibrate
may be rejected for this test method. transmission and test stands by running tests on reference oils.
9.2.5 Countershaft Bearing Preload—Measure the pre-load The purposes are to:
on each of the three countershafts prior to each test as follows: 10.1.1 Verify standardized transmission operation,
9.2.5.1 Assemble the transmission as specified in the Mack 10.1.2 Document a test stand severity level, and
Transmission Service Manual up to and including installing the 10.1.3 Determine the passing limit for a given transmission
yoke on the output shaft. Rotate the transmission so that the and test stand.
shafts are vertical. 10.2 Reference Oils—Two reference oils have been used in
9.2.5.2 Remove the bearing cap from the rear cover for the the development of this test method, a high-quality (passing)
first countershaft to be checked. Measure the thickness of a and a poor-quality (failing) oil. Routine testing is conducted on
0.010 in. (0.254 mm) nominal shim, and record. Add the shim the passing oil. The failing oil is used to verify that test severity
to the shim pack of the shaft, and reinstall the bearing cap. is maintained when new hardware is introduced or a procedural
Torque the bolts to 40 lb-ft to 50 lb-ft (54 N·m to 68 N·m). change could affect severity or when a new stand is being
9.2.5.3 Mount a dial indicator in the main transmission case, calibrated for the first time. Obtain the reference oils from the
and adjust the indicator probe to measure the axial end play of ASTM TMC.
the countershaft. 10.3 Reference Oil Test Frequency—The test stand calibra-
9.2.5.4 Using a pry bar, move the countershaft up to the end tion period is defined as six months or ten tests, whichever
of travel. Release the lifting force, and record the total travel of occurs first. It begins on the completion date of an operation-
the shaft. Repeat this measurement at least three times to ally and statistically acceptable reference oil test as determined
ensure that the values are repeatable. by the TMC. Any test started on or before the stand calibration
9.2.5.5 Mack specifications call for a preload of from expiration date is defined to have been run on a calibrated
0.002 in. to 0.006 in. (0.051 mm to 0.152 mm). To accomplish stand.
this, adjust the shim pack thickness by removing shims equal to 10.4 Instrumentation Calibration—Calibrate the following
the measured end play plus 0.002 in. to 0.006 in. (0.051 mm to instrumentation immediately prior to each set of reference
0.152 mm) additional. tests. Unless otherwise specified in this test method, follow the
9.2.5.6 Repeat this procedure for the other two counter- instructions provided by the manufacturers of the instruments
shafts. Record the measurements on the form in Fig. A7.3 or an regarding the method of calibration. In calibrating each
equivalent. instrument, use certified reference standards, having known
9.2.6 Transmission Torque Measurement— Rotate the trans- values covering the range of measurements to be encountered
mission so that it is in the horizontal position. With the in using this test method, and having tolerances less than those
transmission in low range and dry, measure the break and turn of the measurement tolerances specified in this test method. It
torques by turning the output shaft clamp plate capscrew, with is recommended that the calibration records be retained for a
a torque wrench, in the normal direction of rotation. Make the minimum of 24 months.
measurements three times and report the average of both the 10.4.1 Tailshaft and counter shaft speed measurement
break and turn values (see Fig. A7.3). Continue with the systems,
assembly of the test apparatus. 10.4.2 Temperature sensors and measurement system,
9.2.7 Transmission Coast Down Measurement—With the 10.4.3 Pressure sensors and measurement system, and
drive shaft installed but before attaching the top cover, measure 10.4.4 Shift time measurement system.
the time for the countershafts to coast down from 10.5 Shift Time Calibration—The shift timing system can be
1500 r ⁄min to 500 r ⁄ min, as follows: calibrated by using an oscillograph, or other equally precise
9.2.7.1 Shift the transmission into low range. Using a spray methods, to record the air application event and the counter
bottle charged with the next test oil, spray approximately 1⁄2 oz shaft speeds.
(15 mL) lubricant on each of the main shaft, tail shaft, and six
countershaft bearings. 11. Operating Procedure
9.2.7.2 Start the drive motor and bring up to speed (coun- 11.1 System Flush and Charge:
tershaft at 1750 r/min). Turn off the motor and allow the 11.1.1 Connect all hoses so that the pump, oil heater, and
transmission to coast down to at least 500 r/min. Electronically transmission are connected for testing. Charge the system with
measure the time required for the countershafts speeds to 5 gal (19 L) of test oil. Turn on the pump to circulate oil
decrease from 1500 r ⁄ min to 500 r ⁄ min using a meter capable through the entire system.
of measuring to 0.01 s. See Table 1 for a recommendation. 11.1.1.1 If the test oil is a non-reference oil, first ensure that
Repeat the coast downs until five readings have been obtained. acceptable results on the passing and failing reference oils have
Calculate the average of these five readings, and record the been obtained, and then conduct the non-reference oil test on
readings and their average in the appropriate spaces in Fig. the same hardware configuration used for the reference oil
A7.3. tests.
8
D5579 − 16
11.1.2 With the oil heater turned off, circulate the oil performance of the lubricant. To ensure that the lack of
through the system for a minimum of 10 min. synchronization is not a single non-repeatable occurrence,
11.1.3 Drain the flush oil by removing the drain plug on the terminate the test after two non-synchronized shifts have
transmission and opening the drain valve on the heater. Allow occurred. The passing limits are established by the specifica-
the system to drain for l0 min. tion(s) requiring this test.
11.1.4 Replace the drain plug and charge the system with 12.2 Shifter Fork Wear—Measure shifter fork wear and
5.25 gal (19.9 L) of test oil. Complete the assembly of the test report at the end of test (see Fig. A7.2).
apparatus.
12.3 Test Validity Determination—Calculate the validity of
11.2 Test Operation: the test as described in Annex A5. The test is determined to be
11.2.1 Set the air pressure to 90 psi (621 kPa). Start the operationally valid if the percent deviation of critical operating
drive motor and accelerate the tail shaft to 750 r/min with the parameters, the downtime during the test, and the average total
transmission operating in low range. Turn on the oil heater. cycle time are within the limits specified and defined in Annex
11.2.2 Continue to operate the transmission in low operating A5.
range, not shifting, until the oil temperature is in the operating
range, 250 °F 6 5 °F (121 °C 6 2.7 °C). 12.4 Round test results according to Practice E29.
11.2.3 When the operating temperature is reached, turn on
the automatic shifting cycler, set the cycle timer to zero, and 13. Report
operate under the following conditions: 13.1 For reference oil tests, use the standardized report form
Tailshaft Speed 750 r/min ± 10 r/min set available from the ASTM TMC. Report the non-reference
Cycle Rate 6 s ± 0.3 s high range oil test results on these same forms if the results are intended
6 s ± 0.3 s low range
Air Pressure 90 psi ± 2 psi (621 kPa ± 14 kPa)
to be submitted as candidate oil results against a specification.
Temperature 250 °F ± 5 °F (121 °C ± 2.7 °C) 13.1.1 Fill out the report forms according to the formats
11.2.4 Use the data log sheet shown in Fig. A7.4, or its shown in the data dictionary.
equivalent, for recording all required operating conditions at 13.1.2 Transmit results to the TMC within 5 working days
least once each hour during the test. of test completion.
11.2.5 Using an oscillograph and suitable pressure transduc- 13.1.3 Transmit the results electronically as described in the
ers located as shown on Fig. 6 (see Table 1 for recommended ASTM Data Communications Committee Test Report Trans-
equipment), record the shift activating air pressures input shaft mission Model (Section 2—Flat File Transmission Format)
and countershafts speeds during at least one shift each from available from the ASTM TMC. Upload files via the TMC’s
high to low range and low to high range, during the following website.
periods as applicable: 30 cycles 6 20 cycles, 25 000 cycles 6 13.2 Report all reference oil test results, whether aborted,
300 cycles, 50 000 cycles 6 300 cycles, 60 000 cycles 6 invalidated, or successfully completed, to the TMC.
300 cycles, and a final recording 5000 cycles 6 300 cycles less 13.3 Deviations from Test Operational Limits—Report all
than the average cycles to failure of the most recent five deviations from specified test operational limits
passing reference tests.
11.2.6 Examine these recordings to ensure that the range 13.4 Precision of Reported Units—Use the Practice E29
shift valve and cylinder are operating properly. rounding off method for critical pass/fail test result data.
Report the data to the same precision as indicated in data
11.3 Shut-Down Procedure: dictionary.
11.3.1 Terminate the test when the transmission experiences
two unsynchronized shifts. An unsynchronized shift results in 13.5 In the space provided, note the time, date, test hour,
a clashing of the clutch teeth producing a loud noise (exceeding and duration of any shutdown or offtest condition. Document
114 dB). Alternatively, the test can be terminated after the the outcome of all prior reference oil tests from the current
passing limit established by the applicable specification has calibration sequence that were operationally or statistically
been achieved without a failure. invalid.
11.3.2 Record the final operating conditions, and turn off the 13.6 If a calibration period is extended beyond the normal
shift cycler, oil heater, and drive motor. calibration period length, make a note in the comment section
11.3.3 Drain the test oil from the transmission and heater. and attach a written confirmation of the granted extension from
11.4 Transmission Disassembly—Disassemble the transmis- the TMC to the test report. List the outcomes of previous runs
sion as specified in the Mack Service Manual and inspect for that may need to be considered as part of the extension in the
signs of unusual wear or parts failure. Measure the clutch comment section.
plates and shifter fork (as described in 9.2.4), and record the 13.7 Include in the test report a plot of shift time scaling the
measured wear and visual condition of mating surfaces, using Y-axis from 0 s to 6 s. Plot at least one data point per test hour
the forms shown in Figs. A7.1 and A7.2, or their equivalent. along the X-axis.
9
D5579 − 16
results monitored by the TMC. The data are reviewed annually 14.3 Reproducibility Conditions—Conditions where test re-
by the HTCT Surveillance Panel. Contact the ASTM TMC for sults are obtained with the same test method using the same test
current industry data. (See Table 5.) oil in different laboratories with different operators using
14.2 Intermediate Precision Conditions—Conditions where different equipment.
test results are obtained with the same test method using the 14.3.1 Reproducibility Limit (R)—The difference between
same oil, with changing conditions such as operators, measur- two results obtained under reproducibility conditions that
ing equipment, test stands, test engines, and time. would, in the long run, in the normal and correct conduct of the
test method, exceed the values shown in Table 5 in only one
NOTE 2—Intermediate precision is the appropriate term for this test case in twenty. When only a single test result is available, the
method, rather than repeatability, which defines more rigorous within-
laboratory conditions.
reproducibility limit can be used to calculate a range (test result
6 reproducibility limit) outside of which a second test result
14.2.1 Intermediate Precision Limit (i.p.)—The difference would be expected to fall about one time in twenty.
between two results obtained under intermediate precision
conditions that would, in the long run, in the normal and TABLE 5 Reference Oil PrecisionA
correct conduct of the test method, exceed the values shown in Variable Intermediate Precision Reproducibility
Table 5 in only one case in twenty. When only a single test Si.p.B i.p.C SRB RC
Cycles to Fail 9131 25567 9131 25567
result is available, the intermediate precision limit can be used
A
to calculate a range (test result 6 intermediate precision limit) These statistics are based on results obtained on TMC Reference Oils 151-2 and
151-3 with Configuration 2 hardware over the period from Jan. 25, 1999 through
outside of which a second test result would be expected to fall March 19, 2005.
about one time in twenty. B
S = standard deviation.
C
This value is obtained by multiplying the standard deviation by 2.8.
14.4 This procedure has no bias since the ability of the fluid
to maintain synchronization of gears during shifting is defined
only in terms of this test method.
15. Keywords
15.1 cyclic transmission test; forkwear; manual transmis-
sion lubricants; shifting synchronization; shift time; thermal
stability; total cycle time
ANNEXES
(Mandatory Information)
A1.1 Nature and Functions of the ASTM Test Monitoring Bylaws, the Regulations Governing ASTM Technical
Center (TMC)—The TMC is a non profit organization Committees, the Bylaws Governing ASTM Committee D02,
located in Pittsburgh, Pennsylvania and is staffed to: administer and the Rules and Regulations Governing the ASTM Test
engineering studies; conduct laboratory inspections; perform Monitoring System.
statistical analyses of reference oil test data; blend, store, and
ship reference oils; and provide the associated administrative A1.3 Management of the ASTM TMC—The management of
functions to maintain the referencing calibration program for the Test Monitoring System is vested in the Executive Com-
various lubricant tests as directed by ASTM Subcommittee mittee elected by Subcommittee D02.B0. The Executive Com-
D02.B0 and the ASTM Executive Committee. The TMC mittee selects the TMC Director who is responsible for
coordinates its activities with the test sponsors, the test directing the activities of the TMC.
developers, the surveillance panels, and the testing laborato-
ries. Contact TMC through the TMC Director at: A1.4 Operating Income of the ASTM TMC—The TMC
ASTM Test Monitoring Center operating income is obtained from fees levied on the reference
6555 Penn Avenue oils supplied and on the calibration tests conducted. Fee
Pittsburgh, PA 15206–4489 schedules are established by the Executive Committee and
www.astmtmc.cmu.edu reviewed by Subcommittee D02.B0.
10
D5579 − 16
A2.1 Reference Oils—These oils are formulated or selected A2.4 Analysis of Reference Oil—Unless specifically autho-
to represent specific chemical, or performance levels, or both. rized by the TMC, do not analyze TMC reference oils, either
They are usually supplied directly to a testing laboratory under physically or chemically. Do not resell ASTM reference oils or
code numbers to ensure that the laboratory is not influenced by supply them to other laboratories without the approval of the
prior knowledge of acceptable results in assessing test results. TMC. The reference oils are supplied only for the intended
The TMC determines the specific reference oil the laboratory purpose of obtaining calibration under the ASTM Test Moni-
shall test. toring System. Any unauthorized use is strictly forbidden. The
A2.1.1 Reference Oil Data Reporting—Test laboratories testing laboratory tacitly agrees to use the TMC reference oils
that receive reference oils for stand calibration shall submit exclusively in accordance with the TMC’s published Policies
data to the TMC on every sample of reference oil they receive. for Use and Analysis of ASTM Reference Oils, and to run and
If a shipment contains any missing or damaged samples, the report the reference oil test results according to TMC guide-
laboratory shall notify the TMC immediately. lines. Additional policies for the use and analysis of ASTM
Reference Oils are available from the TMC.
A2.2 Calibration Testing:
A2.2.1 Full scale calibration testing shall be conducted at A2.5 Conducting a Reference Oil Test—When laboratory
regular intervals. These full scale tests are conducted using personnel are ready to run a reference calibration test, they
coded reference oils supplied by the TMC. It is a laboratory’s shall request an oil code via the TMC website.
responsibility to keep the onsite reference oil inventory at or
above the minimum level specified by the TMC test engineers. A2.6 Reporting Reference Oil Test Results—Upon comple-
tion of the reference oil test, the test laboratory transmits the
A2.2.2 Test Stands Used for Non Standard Tests—If a non data electronically to the TMC, as described in 13.1.3. The
standard test is conducted on a previously calibrated test stand,
TMC reviews the data and contacts the laboratory engineer to
the laboratory shall conduct a reference oil test on that stand to
report the laboratory’s calibration status. All reference oil test
demonstrate that it continues to be calibrated, prior to running
results, whether aborted, invalidated, or successfully
standard tests.
completed, shall be reported to the TMC
A2.3 Reference Oil Storage—Store reference oils under
A2.6.1 All deviations from the specified test method shall
cover in locations where the ambient temperature is between
be reported.
–10 °C and +50 °C.
A3.1 Special Reference Oil Tests—To ensure continuous This plan requires all reference oil tests in the program to be
severity and precision monitoring, calibration tests are con- completed as close to the same time as possible, so that no
ducted periodically throughout the year. Occasionally, the laboratory/stand calibration status is left pending for an exces-
majority or even all of the industry’s test stands will conduct sive length of time. In order to maintain the integrity of the
calibration tests at roughly the same time. This could result in reference oil monitoring system, each reference oil test is
an unacceptably large time frame when very few calibration conducted so as to be interpretable for stand calibration. To
tests are conducted. The TMC can shorten or extend calibration facilitate the required test scheduling, the surveillance panel
periods as needed to provide a consistent flow of reference oil may direct the TMC to lengthen and shorten reference oil
test data. Adjustments to calibration periods are made such that calibration periods within laboratories such that the laborato-
laboratories incur no net loss or gain in calibration status. ries incur no net loss or gain in calibration status. To ensure
accurate stand, or laboratory, or both severity assessments,
A3.2 Special Use of the Reference Oil Calibration System— conduct non reference oil tests the same as reference oil tests.
The surveillance panel has the option to use the reference oil
system to evaluate changes that have potential impact on test A3.3 Donated Reference Oil Test Programs—The surveil-
severity and precision. This option is only taken when a lance panel is charged with maintaining effective reference oil
program of donated tests is not feasible. The surveillance panel test severity and precision monitoring. During times of new
and the TMC shall develop a detailed plan for the test program. parts introductions, new or re blended reference oil additions,
11
D5579 − 16
and procedural revisions, it may be necessary to evaluate the mittee D02.B0. In such a case, the TMC issues an Information
possible effects on severity and precision levels. The surveil- Letter. Information Letters are balloted semi annually by
lance panel may choose to conduct a program of donated Subcommittee D02.B0, and subsequently by D02. By this
reference oil tests in those laboratories participating in the means, the Society due process procedures are applied to these
monitoring system, in order to quantify the effect of a particu- Information Letters.
lar change on severity and precision. Typically, the surveillance
panel requests its panel members to volunteer enough reference A3.6.1 Issuing Authority—The authority to issue an Infor-
oil test results to create a robust data set. Broad laboratory mation Letter differs according to its nature. In the case of an
participation is needed to provide a representative sampling of Information Letter concerning a part number change which
the industry. To ensure the quality of the data obtained, donated does not affect test results, the TMC is authorized to issue such
tests are conducted on calibrated test stands. The surveillance a letter. Long term studies by the surveillance panel to improve
panel shall arrange an appropriate number of donated tests and the test procedure through improved operation and hardware
ensure completion of the test program in a timely manner. control may result in the issuance of an Information Letter. If
obvious procedural items affectingtest results need immediate
A3.4 Intervals Between Reference Oil Tests—Under special attention, the test sponsor and the TMC issue an Information
circumstances, such as extended downtime caused by industry Letter and present the background and data supporting that
wide parts or fuel shortages, the TMC may extend the intervals
action to the surveillance panel for approval prior to the
between reference oil tests. Such extensions shall not exceed
semiannual Subcommittee D02.B0 meeting.
one regular calibration period.
A3.7 TMC Memoranda—In addition to the Information
A3.5 Introducing New Reference Oils—Reference oils pro-
duce various results. When new reference oils are selected, Letters, supplementary memoranda are issued. These are de-
participating laboratories will be requested to conduct their veloped by the TMC and distributed to the appropriate surveil-
share of tests to enable the TMC to recommend industry test lance panel and participating laboratories. They convey such
targets. ASTM surveillance panels require a minimum number information as batch approvals for test parts or materials,
of tests to establish the industry test targets for new reference clarification of the test procedure, notes and suggestions of the
oils. collection and analysis of special data that the TMC may
request, or for any other pertinent matters having no direct
A3.6 TMC Information Letters—Occasionally it is neces- effect on the test performance, results, or precision and bias.
sary to revise the test method, and notify the test laboratories of
the change, prior to consideration of the revision by Subcom-
A4.1 New Laboratories—Laboratories wishing to become follows: “COTCO recognizes that D02 has a unique and
part of the ASTM Test Monitoring System will be requested to complex situation. The use of Information Letters is approved
conduct reference oil tests to ensure that the laboratory is using providing each letter contains a disclaimer to the affect that
the proper testing techniques. Information concerning fees, such has not obtained ASTM consensus. These Information
laboratory inspection, reagents, testing practices, appropriate Letters should be moved to such consensus as rapidly as
committee membership, and rater training can be obtained by possible.”
contacting the TMC Director.
A4.3 Precision Data—The TMC determines the precision
A4.2 Information Letters—COTCO Approval—Authority of test methods by analyzing results of calibration tests
for the issuance of Information Letters was given by the conducted on reference oils. Precision data are updated regu-
committee on Technical Committee Operations in 1984, as larly. Current precision data can be obtained from the TMC.
12
D5579 − 16
(S D
n
Mi Ti
percent out 5 3 3 100 (A5.1) A5.1.2.6 Air Pressure:
i51 0.5R D
1 2
where: 3 3 100 5 0.50 % (A5.3)
2 200
Mi = magnitude of test parameter out from specification
limit at occurrence, i, A5.1.3 Average Cycle Time:
R = test parameter specification range, A5.1.3.1 The average total cycle time for a complete test
Ti = length of time the test parameter was outside of shall be within 12 s 6 0.6 s for the test to be considered
specification range at occurrence, i, (Ti is assumed to operationally valid.
be no less than the recorded data-acquisition frequency Average Total Cycle Time5 (A5.4)
unless supplemental readings are documented), and
D = test or test phase duration in same units as Ti. 3600 3 total operating hours of test
NOTE A5.1—A reading out of specification using once-per-hour data total cycles of test
recording is considered to be out for the full hour, unless otherwise
documented. A5.1.3.2 The total cycle time is the time to complete shifts
A5.1.2.3 The deviation percentages for the critical operating from low range to high range and back to low range—
parameters shall not exceed: nominally 12 s.
13
D5579 − 16
A7. MANUAL TRANSMISSION CYCLIC DURABILITY TEST PARTS INSPECTION AND WEAR MEASUREMENTS
14
D5579 − 16
15
D5579 − 16
NOTE 1—Side 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 2—Post-test wear measurement may be made at EOT or at passing cycles. See “Cycles at Wear Measurement” for the point at which the post-test
wear measurement was taken.
FIG. A7.2 Typical Form for Recording Fork Pad Thickness Wear Measurements
16
D5579 − 16
17
D5579 − 16
NOTE 1—Log all shutdowns and repairs on the back of the log sheet.
FIG. A7.4 Data Log Sheet
18
D5579 − 16
SUMMARY OF CHANGES
Subcommittee D02.B0 has identified the location of selected changes to this standard since the last issue
(D5579 – 15) that may impact the use of this standard. (Approved April 1, 2016.)
Subcommittee D02.B0 has identified the location of selected changes to this standard since the last issue
(D5579 – 14) that may impact the use of this standard. (Approved April 1, 2015.)
(1) The purpose of the following changes was to describe more (4) Rewrote Section 13.
clearly the role of the Test Monitoring Center. (5) Added new Annex A1 – Annex A4; renumbered subsequent
(2) Added new Introduction. Annex sections.
(3) Deleted former subsections 10.3.1 through 10.3.1.4, and
10.6.
ASTM International takes no position respecting the validity of any patent rights asserted in connection with any item mentioned
in this standard. Users of this standard are expressly advised that determination of the validity of any such patent rights, and the risk
of infringement of such rights, 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 and
if not revised, either reapproved or withdrawn. Your comments are invited either for revision of this standard or for additional standards
and should be addressed to ASTM International Headquarters. Your comments will receive careful consideration at a meeting of the
responsible technical committee, which you may attend. If you feel that your comments have not received a fair hearing you should
make your views known to the ASTM Committee on Standards, at the address shown below.
This standard is copyrighted by ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959,
United States. Individual reprints (single or multiple copies) of this standard may be obtained by contacting ASTM at the above
address or at 610-832-9585 (phone), 610-832-9555 (fax), or service@astm.org (e-mail); or through the ASTM website
(www.astm.org). Permission rights to photocopy the standard may also be secured from the Copyright Clearance Center, 222
Rosewood Drive, Danvers, MA 01923, Tel: (978) 646-2600; http://www.copyright.com/
19