VW50160_En_062003
Vertragspartner erhalten die Norm nur über die zust?ndige Beschaffungsabteilung.
Confidential. All rights reserved. No part of this document may be transmitted or reproduced without the prior written permission of a Standards Department of the Volkswagen Group.
Parties to a contract can only obtain this standard via the responsible procurement department.
VOLKSWAGEN AG
N o r m v o r A n w e n d u n g a u f A k t u a l i t ?t p r üf e n / C h e c k s t a n d a r d f o r c u r r e n t i s s u e p r i o r t o u s a g e .
T h e E n g l i s h t r a n s l a t i o n i s b e l i e v e d t o b e a c c u r a t e . I n c a s e o f d i s c r e p a n c i e s t h e G e r m a n v e r s i o n s h a l l g o v e r n .
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VW 501 60: 2003-06
4.2 Type
ATF Dexron? III technology, based on mineral oils or unconventional and synthetic hydrocarbons, with additives to improve the friction, viscosity/temperature, wear protection, oxidation protection, foaming and corrosion protection properties.
A summary of the test report on the Dexron? III tests must be submitted.
4.3 Miscibility
Factory-fill-for-life automatic transmission fluids (ATF) according to this specification must be miscible with one another and with factory-fill-for-life automatic transmission fluids according to TL 521 62 in any ratio without limitation. The mixtures must also correspond to all requirements of this specification.
The documentation must be provided for a mixing ratio of 50 : 50.
4.4 Service temperature range (–40°C to +170°C)
See table 1.
Table 1
1 % of the service life +140°C to +170°C
9 % of the service life +120°C to +140°C
90 % of the service life < +120°C
4.5 Service life suitability
The factory-fill-for-life ATF must ensure the operation of the transmission for the entire service life without being changed or supplemented. The specified service life corresponds to a distance of 150,000 km with the permissible gross vehicle weight and a trailer share of 10 % at maximum trailer load.
life
4.6 Shelf
Shelf life in unopened original packaging is ≥24 months at –20°C to + 50°C. The batch number must be given on the label.
4.7 Standard part number
N 052 911 E0
4.8 Spare parts number
G 052 911 A1 / A2 / A6
sample
4.9 Production
The material according to this TL is subject to technical engineering approval.
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VW 501 60: 2003-06 departments
4.9.1 Responsible
Volkswagen AG: EAGA
K-QS-33
procedure
5 Release
5.1 Additive batch testing
If the additive supplier mixes a certain quantity of the finished additive package, this total quantity is designated as an additive batch and given an additive batch number.
Each additive batch must be tested prior to use for mixing the end product. The additive batch is tested and the results documented by the supplier of the service ATF according to section 5.5.
The additive batch is released after the release cycle (Appendix A.1) by the Quality Assurance Department of the ATF supplier.
test
5.2 First-sample
For mixing a first sample, only a checked and released additive batch may be used (section 5.1). The supplier of the service ATF provides 40 liters of the end product mixed under standard production conditions to the Quality Assurance Department of the ordering plant with an Association of German Automotive Industry (VDA) first-sample test report.
This report must contain the results according to sections 6 to 10.
The first-sample release is issued by the Quality Assurance Department of the ordering plant.
5.3 Manufacturing batch testing
If the supplier of the service ATF mixes a certain quantity of the finished product, this total quantity is designated as a manufacturing batch and given a manufacturing report number.
For mixing a manufacturing batch, only a checked and released additive batch may be used (section 5.1).
The manufacturing batch is tested and the results documented by the supplier of the service ATF according to section 5.5.
The manufacturing batch release is issued after the release cycle (Appendix A.1) by the Quality Assurance Department of the service ATF supplier.
If different manufacturing batches (max. 2) are stored in one tank and the shipment is taken from this tank, both manufacturing batch numbers (section 5.4) are to be given on the delivery slip.
batch
5.4 Delivery
If the service ATF supplier removes one or more separate partial quantities from the total quantity of a manufacturing batch at different times and delivers them to the ordering party or stores them, each partial quantity is designated as its own fill batch and given a fill report number in addition to the manufacturing report number.
When delivering in drums, only clean drums must be used. For bulk deliveries, the tank car shall be cleaned before filling.
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VW 501 60: 2003-06
The Quality Assurance Department of the ordering plant receives a plant testing certificate (DIN EN 10 204) with each shipment. The plant testing certificate includes the manufacturing and
fill report numbers as well as the test values according to section 5.5.
5.5 Test
plan
See table 2.
Table 2
Tests Additive
batches
Manufacturing
batches
Delivery batch
Laboratory tests Table 3, No. 1,
No. 2 and No. 5 Table 3, No. 1,
No. 2 and No. 5
to No.10
Table 3, No. 1,
No. 2 and No. 5
to No.10
Pumpability Table 3, No. 12 1) Chemical luminescence analysis Table 4, No. 5.1 1)
Foaming behavior Table 4, No. 6 Air release property Table 4, No. 7 Steady-state temperature Table 5, No. 6.1 1)
DKA coefficient of friction behavior (5 HP-30)
Friction disk 1055 271 053 Coefficient of friction test
(NS 3,000) Section 9.1.1 1) Section
9.1.1
1)
DKA coefficient of friction behavior
(5 HP-24)
Friction disk 1058 270 029
Coefficient of friction test
(NS 3,000)
Section 9.1.2 Section 9.1.2 2)
DKA coefficient of friction behavior (VW AG 4)
Friction disk 095.323.241 A Endurance test (NS 15,000) Section
9.1.3
1)
ZF regulated converter clutch
override test
Section 9.2 Section 9.2
1) These tests must be performed 1 x per year.
2) These tests must be performed on each manufacturing batch.
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VW 501 60: 2003-06
6 Requirements for composition, density and viscosity
See table 3.
Table 3
No. Property Unit Requirement
1 Color/appearance
acc. to ASTM D 6045
≤ 3.5 / colorless, clear
2 IR spectrum
acc. to DIN 51 451
acc. to sample
3 Additive type acc. to sample, see section 10.1
3.1 Additive content % acc. to sample
4 Base oils
4.1 Type and content
(C A, C P, C N)
% to be specified
4.2 Compliance with VW environmental
standard VW 911 01
to be specified
4.3 PAH content acc. to VW 505 50
acc. to PV 1448
to be specified
4.4 Viscosity index of the base oil
acc. to DIN ISO 2909
≥ 145
5 Elements
(Mg, Ca, Ba, Zn, B, N, P, S, Cl)
to be specified
5.1 Calcium (Ca)
acc. to DIN 51 391-2
% 0.0030 ± 0.0005
5.2 Boron (B)
acc. to BAA 202 or PV 1442
% 0.014 ± 0.003
5.3 Nitrogen (N)
acc. to ASTM D 3228
% 0.10 ± 0.01
5.4 Phosphorous (P)
acc. to DIN 51 363
% 0.034 ± 0.004
5.5 Sulfur (S)
acc. to DIN EN ISO 14596
% 0.015 ± 0.005
6 Water content
acc. to PV 1459
mg/kg ≤ 500
7 Density at +15°C
acc. to DIN 51 757 kg/m3
acc. to sample
8 Pour point (P)
acc. to DIN ISO 3016-2 °C max.
-55
9 Dynamic viscosity
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No. Property Unit Requirement 9.1 At –40°C
acc. to DIN 51 398
mPas ≤ 10,000
9.2 At –25°C
acc. to DIN 51 377
mPas ≤ 1,500
10 Kinematic viscosity
acc. to DIN 51 562-1
10.1 At +40°C mm2/s acc. to sample
10.2 At +100°C mm2/s 7.40 ± 0.30
11 Viscosity index
acc. to DIN ISO 2909
≥ 165
12 HTHS viscosity
acc. to CEC-L-36-A-90
mPas ≥ 2.7
13 Pumpability at –40°C (V
oil
/ R oil) acc. to PV 1460 cm3/s 20 % better than VW reference oil section 11.4
7 Characteristics
requirements
See table 4.
Table 4
No. Property Unit Requirement
1 Evaporation loss at +200°C
acc. to DIN 51 581
% ≤ 5
2 Flash point
acc. to DIN ISO 2592
°C ≥ 200
Oil purity
Microscopic particle count
acc. to ISO 4407
3
Purity class
acc. to ISO 4406
19 / 15
4 Corrosivity
acc. to PV 1425
Steel
4.1
Grade
max.
1 Copper
Grade
max.
1 4.2
Weight loss mg/cm2 ≤ 2.0
4.3 Sludge formation of the oil-water
mixture not
permissible
5 Oxidation stability
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VW 501 60: 2003-06
No. Property Unit Requirement
Chemical luminescence analysis
acc. to PV 1476
At 190°C s ≥ 850
5.1
At 220°C s ≥ 120
Oxidation test
acc. to CEC-L-48-A-97/B
(192 h; 5 l air/h; +170°C; 100 ml)
5.2
After testing is completed, the following requirements must be met:
5.2.1 Blotter-spot test / drippage area no solid or sticky residues
5.2.2 ? viscosity at +100°C
acc. to DIN 51 562-1
% ≤ 10
5.2.3 ? TAN
acc. to ASTM D 664 mg
KOH/g
to be specified
6 Foaming behavior
acc. to ASTM D 892
6.1 New oil
6.1.1 At +25°C / after 20 s ml ≤ 20 / 0 6.1.2 At +95°C / after 20 s ml ≤ 50 / 0 6.2 After aging
acc. to CEC-L-48-A-97/B
(24 h at +140°C)
6.2.1 At +25°C / after 20 s ml ≤ 20 / 0 6.2.2 At +95°C / after 20 s ml ≤ 50 / 0
Air release property at +50°C
acc. to DIN 51 381
After aging
per CEC-L-48-A-97/B
(24 h at +140°C)
Air-in-oil dispersion
(requirements based on
DIN 51 381)
After 0 min (extrapolated) vol. % ≤ 3.5
After 1 min vol. % ≤ 2.5
After 2 min vol. % ≤ 1.8
After 3 min vol. % ≤ 1.2
7
0.2 volume percent after min. ≤ 8
8 Shear stability
acc. to CEC L-45-A-99
Viscosity after shearing acc. to DIN 51 562-1 mm2/s ≥ 7.0
8.1
Shear loss % ≤ 5
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VW 501 60: 2003-06
No. Property Unit Requirement
HTHS viscosity
acc. to CEC L-36-A-90 after mechanical shearing acc. to CEC L-45-A-99 mPa.s ≥ 2.70
8.2
Shear loss % to be specified
8 Functional
requirements
See table 5.
Table 5
No. Property Unit Requirement
1 Elastomer compatibility
(static inclusion tests)
see section 9.2
Tensile strength
acc. to DIN 53 504
relative change
Test elastomer 1 % ± 25
Test elastomer 2 % ± 0 to –50
Test elastomer 3 (test temperature +100°C)% ± 0 to –50
Test elastomer 4 % ± 0 to –50
1.1
Test elastomer 5 % ± 30
Elongation at tear
acc. to DIN 53 504
Relative change
Test elastomer 1 ± 30
Test elastomer 2 ± 0 to –50
Test elastomer 3 (test temperature +100°C)± 0 to –50
Test elastomer 4 ± 0 to –30
1.2
Test elastomer 5 ± 35
1.3 Cracks at 100 % elongation not permissible
2 Elastomer compatibility
(dynamic radial shaft seal tests)
Test run with ACM radial shaft seal
see section 9.3
2.1
After testing is completed, the following requirements must be met:
2.1.1 Leakage
none
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VW 501 60: 2003-06 No. Property Unit Requirement
2.1.2 Sealing lip wear mm ≤ 0.4
2.1.3 Radial force loss % ≤ 30
2.1.4 Oil deposits and discoloration of the
radial shaft seal Slight, soft oil residues permissible
Cracks on the sealing lip at ~ 50 % elongation none
2.1.5
No indication specified, see VW 011 50 ff
3 Compatibility at 100°C with respect to
thrust washer composite material
acc. to PV 1471 μ1 > μ2≥ μ3
friction coefficient profile between μ1 and μ3
always ≥ μ3
3.1 PPA Friction-
oscillatio
n factor
≤ 0.12
4 Pitting load-bearing capacity (FZG
pitting test)
acc. to PT C/9/90 h ≥ 150
(3 trials/individual values must be
indicated)
Gray stippiness
VW reference oil see section 9.4 to be specified
Oil under test better than VW reference oil
section 9.4
4.1
Profile notes must be submitted
5 Limit of load capacity
(FZG test A/16.6/90)
acc. to DIN 51 354-2
SKS ≥ 11
6 Fuel economy
6.1 Steady-state temperature
acc. to PV 1454 > 5°C better than VW reference oil section 9.4
6.2 Loss coefficient V
G
acc. to PV 1456 5 % better than VW reference oil section 9.4
9 Functional requirements/friction behavior
9.1 DKA friction coefficient test
The friction coefficient test is performed on two selected clutches from the transmissions 5 HP-18 and 5 HP-30, made by Zahnradfabrik Friedrichshafen (ZF), and on one clutch from the VW transmission VW AG 4.
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9.1.1 Transmission 5 HP-18
9.1.1.1 Specimen parts 5 HP-18, clutches F/G
─Friction disk ZF no. 1056 277 036 / SD 1798 BM
─Steel disk ZF no. 1056 377 003
The specific references batches listed by ZF are to be used. The batch numbers of the friction and steel disk batches must be specified on the test log.
9.1.1.2 Measurement of dynamic, static and quasistic friction coefficients
─Short coefficient of friction test, measurement at shift number:
10, 20, 50, 100, 200, 300, 400, 500
─Coefficient of friction test, measurement at shift number:
10, 20, 50, 100, 200, 300, 400, 500, 1,000, 2,000, 3,000
─Endurance coefficient of friction test, measurement at shift number:
10, 20, 50, 100, 200, 300, 400, 500, 1,000, 2,000, ..., 10,000
The thickness of the friction disks is measured according to ZF-PRA 0000 700 875 before the beginning and after the end of the test.
9.1.1.3 Test conditions at 100 % load (testing note 10.8)
See table 6.
Table 6
Testing parameter Unit Short
coefficient
of friction test
Coefficient of
friction test
Endurance
coefficient of
friction test
Speed rpm 2,330
Disk pressure N/mm2 0.80
Specific work J/mm2 0.60
Number of friction
surfaces
8 Shift frequency h-1 120 Closing time s 5
Specific oil
flow rate
mm3/mm2/s 0.75
Oil flow rate l/min 1.0
Oil feed
temperature
°C 80 ± 3
Number of shift operations (NS) 500 or until
constant
coefficient of
friction reached,
see section 10.5
3,000 10,000
Total release
clearance
mm 1.4
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VW 501 60: 2003-06
9.1.1.4 Influence of the oil temperature and surface pressure on the coefficient of friction
A special temperature-pressure test (T-P test) is run according to section 10.9 to determine the dependence of the coefficient of friction on the oil temperature and the surface pressure.
9.1.1.5 Friction coefficient tolerances
─Dynamic coefficient of friction Shift no. 10 to 10,000 Shift operation start, see section 11.7 0.120 to 0.150
Shift operation end, see section 11.6 0.120 to 0.150
Friction coefficient difference within one shift operation ≤ 0.020
─Static coefficient of friction 0.130 to 0.170
─Quasistatic coefficient of friction 0.090 to 0.130
9.1.1.6 Wear limit values
Permissible decrease in thickness per friction disk (average of 5 measurements).
─After short coefficient of friction test (500 shift operations) ≤ 0.040 mm
─After coefficient of friction test (3,000 shift operations) ≤ 0.050 mm
─After endurance coefficient of friction test (10,000 shift operations) ≤ 0.060 mm
9.1.2 Transmission 5 HP-30
9.1.2.1 Specimen parts 5 HP-30, clutches B/D/E2
─Friction disk ZF no. 1055 271 053 / Dynax D-0580-30
─Steel disk ZF no. 1055 371 003
The specific references batches listed by ZF are to be used. The batch numbers of the friction and steel disk batches must be specified on the test log.
9.1.2.2 Measurement of dynamic, static and quasistic friction coefficients
─Short coefficient of friction test, measurement at shift number:
10, 20, 50, 100, 200, 300, 400, 500
─Coefficient of friction test, measurement at shift number:
10, 20, 50, 100, 200, 300, 400, 500, 1,000, 2,000, 3,000
─Endurance coefficient of friction test, measurement at shift number:
10, 20, 50, 100, 200, 300, 400, 500, 1,000, 2,000, ..., 10,000
The thickness of the friction disks is measured according to ZF-PRA 0000 700 875 before the beginning and after the end of the test.
9.1.2.3 Test conditions at 100 % load (testing note 10.10)
See table 7.
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VW 501 60: 2003-06
Table 7
Testing parameter Unit Short
coefficient
of friction test
Coefficient of
friction test
Endurance
coefficient of
friction test
Speed rpm 2,500
Disk pressure N/mm2 0.5
Specific work J/mm2 0.60
Number of friction
surfaces
6
Testing parameter Unit Short
coefficient
of friction test
Coefficient of
friction test
Endurance
coefficient of
friction test
Shift frequency h-1 120 Specific oil
flow rate
mm3/mm2/s 0.75
Oil flow rate l/min 1.7
Oil feed
temperature
°C 80 ± 3
Number of shift operations (NS) 500 or until
constant
coefficient of
friction reached,
section 10.5
3,000 10,000
Total release
clearance
mm 1.1
9.1.2.4 Influence of the oil temperature and the surface pressure on the coefficient of
friction
A special temperature-pressure test (T-P test) is run according to section 10.11 to determine the dependence of the coefficient of friction on the oil temperature and the surface pressure.
9.1.2.5 Friction coefficient tolerances
─Dynamic coefficient of friction Shift no. 10 to 10,000
Shift operation start, see section 11.7 0.130 to 0.190
Shift operation end, see section 11.6 0.115 to 0.155
Diff. betw. max. friction coeff. at shift start and min. friction coeff. ≤ 0.050
Diff. betw. max. friction coeff. at shift end and min. friction coeff. ≤ 0.015
Friction coefficient difference within one shift operation ≤ 0.020
─Static coefficient of friction 0.135 to 0.160
─Quasistatic coefficient of friction 0.095 to 0.120
9.1.2.6 Wear limit values
Permissible decrease in thickness per friction disk (average of 5 measurements).
─After short coefficient of friction test (500 shift operations) ≤ 0.040 mm
─After coefficient of friction test (3,000 shift operations) ≤ 0.050 mm
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VW 501 60: 2003-06
─After endurance coefficient of friction test (10,000 shift operations) ≤ 0.060 mm
9.1.3 Transmission VW AG 4
9.1.3.1 Specimen parts VW AG 4, clutches
─Friction disk VW no. 095.323.241 A
─Steel disk VW no. 095.323.139
The batch numbers of the friction and steel disk batches must be specified on the test log.
9.1.3.2 Measurement of dynamic, static and quasistic friction coefficients
─Endurance coefficient of friction test, measurement at shift number:
100, 200, 500, 1,000, 2,500, 5,000, 7,500, 10,000, 12,500, 15,000
The thickness of the friction disk is measured before the beginning and after the end of the test.
9.1.3.3 Test conditions at 100 % load (section 10.12)
See table 8.
Table 8
Testing parameter Unit Endurance coefficient
of friction test
Speed rpm 6,300 Disk pressure N 2,000
Specific work J/mm2 0.50
Number of friction surfaces 10
Shift frequency h-1 120
Oil flow rate l/min 1.0
Oil feed temperature °C 120 ± 3
Number of shift operations (NS) 15,000
Total release clearance mm 1.5
9.1.3.4 Friction coefficient tolerances
─Dynamic coefficient of friction
─Shift operation start, see section 10.7 0.130 to 0.190
─Shift operation end, see section 10.6 0.115 to 0.155
─Diff. betw. max. friction coefficient at
shift start and min. friction coefficient ≤ 0.050
─Diff. betw. max. friction coefficient at
shift end and min. friction coefficient ≤ 0.015
─Static coefficient of friction 0.135 to 0.160
─Quasistatic coefficient of friction 0.095 to 0.120
9.1.3.5 Wear limit values
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VW 501 60: 2003-06
Permissible decrease in thickness per friction disk (average of 5 measurements):
─After endurance coefficient of friction test (15,000 shift operations) ≤ 0.060 mm
9.2 ZF Sachs regulated converter clutch override test
(or section 9.3; ZF regulated converter clutch override test)
Schematic representation see section 10.13.1.
parts
9.2.1 Specimen
─Friction disk ZF Sachs no. 0784 063 000 (BW SD 1473-2)
The batch numbers of the friction and steel disk batches must be specified on the test log.
─Converter cover ZF Sachs no. 0083 014 980 (flange cover)/bypass Grooves, made from ZF Sachs no. 0783 181 000 (used for max. 10 test runs)
─Converter piston ZF Sachs no. 0784 062 100 (new)
Test conditions (section 10.13) See table 9.
Table 9
Testing parameter Unit Endurance coefficient
of friction test
Speed rpm 800 to 0
Clutch pressure bar 3.5
Disk pressure N/mm2 2.5
Specific work J/mm2 0.6
Number of friction surfaces 2
Shift frequency h-1 120 Oil feed temperature °C 110 ± 5
Number of shift operations (NS) 5; 505 or to constancy of the
coefficient of friction Total release clearance mm 0.3
Recording of the coefficient of friction of switching actuation 5 and 505 at speed:
550, 400, 120, maximum value between 50 and 0 or no maximum value at 50 and 1.2 rpm
9.2.2 Specific coefficient of sliding friction test (regulated converter clutch override test)
a) Test conditions
See table 10.
Table 10
Testing parameter Unit Endurance coefficient
of friction test
Speed rpm 0 to 100
Clutch pressure No. 1 bar approx. 2.8
Disk pressure No. 1 N/mm2 1.9
Clutch pressure No. 2 bar approx. 1.6
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VW 501 60: 2003-06 Testing parameter Unit Endurance coefficient
of friction test
Disk pressure No. 2 N/mm2 1.1
Torque rate of rise Nm/s 100
Number of friction surfaces 2
Shift frequency h-1 120 Oil feed temperature °C 110 ± 5
Number of shift operations (NS) 3
Total release clearance mm 0.3
With a closed converter clutch and at constant pressure, the torque is increased steadily until the converter clutch breaks away and the speed reaches 100 rpm. Torques and speeds are recorded.
The measurements are taken after shift operations 5 and 505 at clutch pressures no. 1 and no. 2.
The coefficient of sliding friction test is conducted 3 times in succession for each setting. The friction coefficient profile is assessed at shift operation no. 3 between 0 and 100 rpm for the evaluation.
b) Limit values (section 10.16)
─Coefficient of friction at 5 rpm 0.120 to 0.125
(Clutch pressure no. 1, shift operation 505)
─Profile until speed 120 rpm monotonically rising
9.3 ZF regulated converter clutch override test
Schematic representation see section 10.7.
parts
9.3.1 Specimen
─Friction disk ZF no. 9907 870 120 (BW SD 1473-2)
The batch numbers of the friction and steel disk batches must be specified on the test log.
─Converter cover ZF Sachs no. 0783 181 000/bypass grooves
─Converter piston ZF Sachs no. 0784 062 100/bypass grooves
conditions
9.3.2 Test
See table 11.
Table 11
Testing parameter Unit Endurance coefficient of friction
test
Difference speed rpm 40
Disk pressure N/mm2 0.9
Clutch torque Nm 160
Oil feed temperature °C 120 ± 5
Permanent slip time min. 20
Flushing and cooling time min. 1
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VW 501 60: 2003-06
9.3.3 Vibration behavior measurement
The drive torque with superimposed friction vibrations is to be measured throughout the entire test.
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VW 501 60: 2003-06
9.3.4 Limit values (sections 10.16 and 10.17)
─Vibration time at start of test ≤ 3 min
─Subsequent vibration-free time ≥ 25 h
─Friction coefficients at 5 rpm 0.120 to 0.125
10 Notes on testing, explanations
The requirement "according to sample" is a quality specification of a released sample.
The requirement "to be specified" is for the general information of the sample presented, from
which a concrete requirement can be derived later.
10.1 Released additive types
"Hitec 403" by Ethyl Mineral?l-Additive GmbH
10.2 Sources of supply for reference elastomers
Test specimens: S3A according to DIN 53 504; test duration: 192 h; test temperature: +150°C;
specimen/oil ratio according to PV 3323: 1:80.
─Test elastomer 1: “70 ACM/121433” by Freudenberg Dichtungs- und
Schwingungstechnik
KG
─Test elastomer 2: "FKM E-281" by Parker-Pr?difa GmbH
─Test elastomer 3: "NBR 28" by Bayer AG
─Test elastomer 4: "VMQ E-151" by Bayer AG
─Test elastomer 5: “AEM 11621” by Dichtungstechnik Bruss GmbH
10.3 Test run with ACM radial shaft seal
See table 12.
Table 12
Drawing No. 02M 301 189 B
Number 6 Running time h 245 (10 cycles) Radial runout deviation mm ≤ 0.15
One test cycle consists of 3 steps according to table 13.
Table 13
Step no. Test duration
h : min.
Temperature
°C
Speed
rpm
Direction
of rotation
1 14 : 00 +110 2,000 right or left
2 06 : 00 +130 2,000 right or left
3 04 : 00 +25 0 at rest
After the temperature stage of +130°C in the 5th cycle, a peak temperature of +150°C is to be reached one time for 5 h. The entire run time is thus 245 h.
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VW 501 60: 2003-06
10.4 VW reference oil
“LT 71 141” by EXXON-MOBIL.
10.5 Friction coefficient constancy
Friction coefficient constancy is reached when the coefficient of friction does not change in form or
amount by more than 2% over 100 consecutive shift operations at full load.
For the first-sample test, coefficients of friction are also determined in the partial load range
(20 to 50 % load) (section 10.10).
10.6 Friction coefficient profile
The entire friction coefficient profile must be within the specified tolerance range, which is defined
by the combination of the upper and lower limit values.
10.7 Friction coefficient profile
The entire friction coefficient profile must be within the specified tolerance range, which is defined
by the combination of the upper and lower limit values. The entire friction coefficient profile must
rise monotonically.
10.8 Test conditions for coefficient of friction test (disk size: 5 HP-18 FL / F,G)
See tables 14 and 15.
Table 14
Number of friction disks 4
ZF friction disk no. 1055 277 036
ZF steel disk no. 1056 377 044
Steel disk thickness mm 1.8
Number of friction surfaces 8
Lining outside/inside diameter mm 135.00 / 121.00
Friction surface mm2 2,815
Mean radius m 0.0641
Release clearance per friction
mm 0.17 surface
Clutch release clearance mm 1.4
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VW 501 60: 2003-06
Table 15
Parameter
Unit
100 % load
50 % load
20 % load
Dynamic coefficient of friction
dn rpm 2,330 4,590 1,890
c m
m/s 15.6 30.79 12.68
J kgm2 0.453 0.078 0.172
Additional flywheel mass
27 KW DKA 2 + 3 - 5+6 50 KW DKA
J2D
-
J1A
p R N/mm2 0.80 0.35 0.35
F s N 2,250 990 990
μm 0.14 0.15 0.15
q A J/mm2 0.60 0.40 0.15
q 0.1 W/mm2 1.25 1.08 0.44
t R s 0.69 0.49 0.45
t S
s 30 30 30
Static coefficient of friction
dn rpm 2 2 2
c m m/s 0.01 0.01 0.01
p R N/mm2 0.80 0.35 0.35
F s N 2,250 990 990
Oil
th oil
°C
80
100
100
v. mm/s 0.75 0.75 0.75 v. l/min 1.0 1.0 1.0
Number of shift
operations
500 500 500
─ Lining thickness measurement New condition, after 500 shift operations ─ Visual inspection
After test completion
─
Calculation of friction coefficients
10, 20, 50, 100, 200, ..., 500
Page 20
VW 501 60: 2003-06
10.9 Temperature-pressure test (disk: 5 HP-18 F, G) See table 16.
Table 16
Shift operation
Dyn.
friction
coefficie
nt
100 %
load
Static
coeffici
ent of
friction
Pressure (N/mm2) Temperature (°C)
No. Qty. 8.0 4.0 1.2 30 50 80 100 120
1 10 X X
11 1 X X X
12 1 X X X
13 1 X X X
14 10 X X
24 1 X X X
25 1 X X X
26 1 X X X
27
10 X X
37 1 X X X
38 1 X X X
39 1 X X X
40
500 X X
540
10 X X
550
1 X X X
551 1 X X X
552
1 X X X
553
10 X X
563 1 X X X
564 1 X X X
565 1 X X X
566
10 X X
576
1 X X X
577 1 X X X
578
1 X X X
579 10 X X
589 1 X X X
590 1 X X X
591 1 X X X
592
10 X X 602
1 X X X 603 1 X X X 604
1 X X X