Gearbox ZIL-130: device, characteristics and principle of operation

2024 Author: Erin Ralphs | [email protected]. Last modified: 2024-02-19 11:41

A lot of legendary trucks were produced at the Likhachev Automobile Plant. These include the 130th model. Let's pay attention to one of the most important mechanisms in the design of a car. The ZIL-130 gearbox is a complex unit that is structurally and functionally different from most other analogues. For proper management and extension of the operating life of the node, it is necessary to have an idea about its design and operation scheme. These nuances, as well as methods of repair and maintenance, will be discussed below.

ZIL-130 gear box

The car is equipped with a three-way mechanical transmission unit with multiple operating ranges. Five speeds are designed to move forward, one mode is reverse. The unit has a pair of inertial configuration synchronizers. The primary (drive) shaft is mounted in the crankcase of the box, aggregating with a helical gear and a corolla responsible for activating the transmission.

In the boring part of the specified element, a roller bearing mechanism of a cylindrical type is installed. A secondary pulley is placed on it with the front side. In the bottom compartmenthousing has an intermediate shaft with a gear. Three more similar parts are mounted on the secondary pulley.

Gearbox shaft ZIL-130

A spur gear is provided on the splines of the node in question, which serves to engage the first and reverse gears. The block of carriages for the synchronizing mechanism is located in the same area.

On the secondary shaft, oblique gears are provided for switching on the second, third and fourth speeds. They are located in such a way as to be in constant engagement with similar elements of the intermediate roller. An axle is rigidly fixed in the lower part of the crankcase of the assembly. It has a reverse speed device with spur gears. They aggregate with cylindrical roller bearings.

The large gear engages in stable engagement with a special piece on the countershaft. Inside the crankcase is filled with working fluid (gear oil). This section is protected by a cover that houses the gearshift system.

Working principle

Gear shifting on the ZIL-130 is based on a kinematic scheme with the operation of synchronizers and gears. When squeezing out the first speed, the corresponding gear element moves along the splines, entering into interaction with the first gear element on the intermediate shaft. From the primary analogue, the torque is transformed to the secondary pulley using constant mesh gears. Gear ratio - 7, 44.

When you turn on the second speed at the ZIL-130 gearbox, the synchronizer clutch gets into engagement with the internal teeth of the working gear. After that, torque is transmitted on the intermediate shaft by means of a primary analogue and a block of gear mechanisms. Force is exerted on the secondary shaft using a synchronizer. Gear ratio - 4, 1.

During the activation of the third gear, the corresponding clutch loses engagement with the gear, moves along the splines, starting to aggregate with the working teeth. At the same time, it is already in interaction with the element of the third speed of the intermediate block. From the primary pulley, the force is transformed with the help of gears and gear elements, transmitted further to the input shaft through the clutch. The working number is 2, 29.

Activate other speeds

Briefly, the further operation of the ZIL-130 gearbox can be described as follows:

• When the fourth speed is activated, the synchronizer works, the clutch of which moves, engaging with the corresponding gear teeth. The force of the gear ratio (1, 47) is carried out by means of intermediate gears on the secondary shaft.
• The inclusion of fifth gear is accompanied by a similar procedure for the operation of teeth, synchronizers and their elements of the corresponding part. In this case, both shafts form a single structure that allows you to transfer force to the cardan element.
• When the reverse gear of the ZIL-130 gearbox is activated, a special carriage enters into operation. The transmission of torque is carried out by means of a gear mechanism, whilethe direction of rotation changes.

Scheme of work

Below is a schematic representation of the functioning of the node in question with explanations:

• a – transmission device;
• b, c, d, e, f, g - first / second / third / fourth / fifth / reverse speed;
• 1, 4, 6, 7, 8, 10, 11, 14, 15, 16, 18, 19 - helical gears;
• 2 - drive shaft;
• 3 - output shaft;
• 5, 9 - synchronizer carriages;
• 12 - block of spur gears;
• 13 – axis;
• 17 - intermediate plan gear;
• 20 - crankcase.

DIY Repair

To repair the specified assembly and adjust the ZIL-130 clutch, a special stand will be required.

Assembly of transmission units is carried out in the following order.

1. The ball bearing mechanism is being mounted, for which the retaining ring is placed in the provided groove of the block.
2. The bearing is mounted in a special seat on the drive shaft, with the undercut of the element facing outward.
3. After placing the main shaft on the stand table, the bearing device is pressed in using a special machine. In addition, you will need a mandrel, through which the element is driven into the shaft neck until it stops.
4. Using a torque wrench, tighten the nuts with a force of 20 kgm. The collar must fit into the groove of the primary roller.
5. The internal parts of the gears are treated with solid oil or its analogue, theninstall roller bearings. The last element should be mounted without interference. After the procedure, they perform diagnostics for the free rotation of parts, without falling out of their nests.
6. Retaining ring mounted.
7. Before assembling the synchronizers of the second and third speeds of the ZIL-130 gearbox, three fixing supports are placed in the mechanism, with the milling part outward.
8. Next, you will need to align the holes of the above parts. Then the rings are pressed in.
9. Assemble three fasteners using springs and balls, which are mounted in the provided sockets of the carriage. Similar work is carried out with the second ring installed on the locking fingers.

Assembly of intermediate shaft

This ZIL spare part is assembled in the following sequence:

• gears are pressed in;
• a layer of lubricant is applied to the splines;
• the key and gear mechanism of the second speed are installed in the corresponding groove;
• the shaft is fixed on a special stand;
• required force is provided by the brake chamber rod, adjustable handle on the pneumatic valve.

Repair of drive shaft

The specified part of the ZIL-130 gearbox is assembled on the table. In this case, the thread should look down. Grease is applied to the splines. Next, the first speed gear is installed, the hub groove is directed towards the front of the input shaft. Correct assembly is determined bychecking the presence of its free play on the splined elements.

Grease is also applied to the neck, the second speed gear is mounted, while the ring gear is turned towards the front edge of the secondary pulley. Solidol is treated with a thrust washer, which is placed in a seat with a retaining ring. The gap between the side of the hub and the specified part should not exceed 0.1 mm. The gear, when correctly installed, will rotate freely by hand.

Installing timing and other parts

Further assembly of the ZIL spare part (drive shaft) continues in the following order.

1. The second and third speed synchronizers are placed on the shaft so that the side groove of the carriage looks towards gear 2.
2. Lubricant is applied to the neck, after which the third speed gear is mounted on the input shaft. In this case, the slotted hole is directed to the synchronizer.
3. Treat the thrust washer with grease, install it on the shaft. It should be tightly clamped between the sleeve and the side of the driven roller (use press-on).
4. Lubricate the neck, mount the fourth gear, check the correct position by rotating the part around its own axis.
5. The gap between the sidewall of the flange and the washer is maintained no more than 0.1 mm.
6. Installation is correct if the carriage moves freely along the slots.

Gear shift mechanism

ZIL-130 characteristics provide for the assembly of the switching unit using a special tool that can be found at the service station.

The process flow diagram looks like this.

1. The transmission cover is fixed in the device. On the end of the tool there is a hole into which the plug is placed using a mandrel and a hammer, hitting the center of the element.
2. Assemble the breather, then screw it into the cap.
3. A pair of mounting bushings are pressed in.
4. Fixing springs are mounted in special grooves.
5. The ball is placed in the left socket using the beard.
6. The first and reverse gear activation rod is mounted, having previously applied gear grease to the part.
7. Install the stem into the inside of the cover, while the mounting hole should overlap. Next, put the head and fork of the first and second speeds. The hub is directed towards the holes with plugs.
8. Move the stem until the fixation ball and the neutral range socket are aligned with each other. Before this, blocking elements are mounted in pairs.
9. Since the dimensions of the ZIL-130, as well as the mass, are quite impressive, the safety heads should be fixed securely, additionally fixing them with locking bolts. Then cotter pins and plugs are placed.

Shift Lever

This is the last assembly in the gearbox assembly (its characteristics from ZIL-130 are discussed above). The procedure is as follows.

• The selector housing is installed on a specialmachine or in a vice.
• The locking piece is placed in the socket on the crankcase of the unit, a cover is put on the selector, put it in its place.
• A spherical surface is treated with a layer of lubricant. A spring is driven behind the crankcase studs, which is installed together with the support of the ball element.
• Assemble the intermediate lever of the first and second speed.
• The handle is fixed with a nut, and the gasket is fixed on the gearbox cover with sealant.
• In the final, the intermediate part is mounted in a special slot on the stem head. The second analogue is placed in the groove of the fork. The lever is attached to the body by means of special clamps with spring-type washers.