How the front and rear axles of the ZIL-131 truck are arranged

Characteristics and weight of the ZIL 131 car

Parameters of the truck in question:

• length/width/height (mm) - 7040/2500/2510;
• wheelbase (mm) - 3350/1250;
• ground clearance (under the front axle/in the area of ​​intermediate and rear drive) (mm) - 330/355;
• wheel track front and rear (mm) - 1820;
• minimum turning radius (mm) - 1002;
• tires - 12.00/20;
• cargo platform dimensions (mm) - 3600/2320/569;
• loading height (mm) - 1430;
• weight of empty ZIL 131 (curb) (kg) - 5275 (6135);
• load capacity indicator (on highway/dirt road) (t) - 5.0/3.5;
• total weight of the truck with winch (kg) - 10425.

The load on the road from the mass of the vehicle is distributed as follows: front axle - 2750/3045 kgf, rear bogie - 3385/3330 kgf.

Power units

The serial onboard ZIL 131, the weight of which is indicated above, was equipped as standard with a four-stroke carburetor engine with 8 cylinders and a volume of 6 liters. The nominal power is 150 “horses”, the average fuel consumption is 36-39 l/100 km. The engine belongs to the overhead valve category and has liquid cooling.

In 1986, they began installing an improved power unit with a capacity of 150 horsepower on some modifications. It differed from its predecessor in the cylinder block, the heads of which received screw-type intake valves and increased compression (7.1). In addition, the engine has become more economical than its standard counterpart.

Diesels were rarely installed on this truck. For these purposes, the following types of motors were used:

1. D-245.20. Engine with in-line placement of four cylinders, volume 4.75 liters. Power - 81 hp. s, fuel consumption - 18 l/100 km.
2. ZIL 0550. Own-produced power unit with four strokes, volume 6.28 liters, power rating 132 hp. With.
3. YaMZ-236. V-shaped engine with six cylinders, volume 11.1 liters, power 180 “horses”.

Features of the engine and gearbox

ZIL-131 has a V-shaped carburetor engine with 8 cylinders, a power of 150 l/s and 3 drive axles. The front axle is controlled by electric pneumatics.

The ZIL-131 truck is not economical in terms of fuel consumption. For this reason, the AI-76 grade is usually used for its operation. Consumption per 100 km is about 40 liters. The increase in the indicator while driving is influenced by the features of the relief surface on which vehicles move. To increase fuel efficiency, many owners replace the gasoline engine with a diesel engine, which has a volume of 4.7 liters and a power of 109 l/s.

ZIL-131 includes a manual transmission and manual gearbox, with a 5 liter volume of engine fluid. If the design is strengthened by a power take-off (PTO), then the displacement increased to 6.5. RCPs were installed on the ZIL-131 for greater stability at low speeds. When such innovations are introduced, the largest possible moment of force is generated in the system.

Steering and brakes

The truck in question is equipped with a power steering system, placed in a common compartment with a control mechanism. The last element is a working pair with a screw and a nut on hinges, as well as a rack with gearing. The hydraulic booster pump is a plate type and is driven into rotation by the crankshaft pulley belt. Longitudinal-transverse rods - with heads on ball elements, are equipped with self-clamping crackers.

The truck's brakes are drum brakes with a pair of internal pads. The parts are released using a cam mechanism located on all wheels. The diameter of the drum is 42 centimeters, the width of the pads is 10 cm. When the brake system is activated, the pneumatics are activated, without axial separation. The parking block is mounted on the transmission shaft, also of the drum type. The braking distance at a speed of 60 km/h is approximately 25 meters.

How does the gearbox of a car of this brand work?

When the first speed is activated on the gearbox of a car model 130 and 131, the gear wheel begins to move along the grooves and engages with the cardan of the first gearbox mode on the intermediate shaft. In this case, the torque begins to transfer from the primary pulley through gears and other auxiliary elements to the secondary disk. The gear ratio is 7.44.

When the driver engages second speed, the clutch mounted on the synchronizer begins to act on the gear teeth of this transmission. As a result of the fact that this component is already functioning from the components of the intermediate gear, the torque begins to transfer from the primary element to the secondary element. In this case, the moment passes through all the wheels with teeth, as well as the synchronizer cardan. In this case, the gear ratio will be 4.1.

When the driver activates third speed, the synchronizer disc stops affecting the parts and elements of the second gear. The clutch will move along the splines and engage with the third-mode component of the gearbox of models 130 or 131. And this element, in turn, is already engaged with the third-speed wheel of the intermediate cardan. Thus, the torque begins to transfer from the primary pulley through auxiliary elements and the clutch to the secondary pulley. The gear ratio is 2.29.

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When the fourth mode is activated, the corresponding synchronizer begins to function. The clutch of this component will move and engage with the gears of the corresponding gearbox mode, which, in turn, is already engaged with the PV wheel. In principle, the process of moving torque is identical to that described above - the torque is supplied to the secondary pulley. Here the gear ratio will be 1.47.

Then, when the driver decides to engage the fifth mode, the synchronizer clutch will engage with the corresponding fourth-speed disc. Further, moving through the movement of the teeth on the PV, the coupling connects both disks into one and it begins to move. In this case, it is carried out on the cardan of model 130 or 131. The gear ratio will be equal to 1.

In general, the process of activating reverse gear is identical to those described above. Only in this case will torque be transmitted from the primary to the secondary through all six gears, and the gear ratio will be 7.09. As you can see, the operating principle of the unit as a whole is not particularly complicated and is quite similar to a traditional mechanical transmission, the difference lies only in certain points.

Transfer case ZIL-131 device

The ZIL-131 transfer case converts and distributes the torque received from the gearbox to the front and rear axles, and, ultimately, to the wheels of the truck.

Front-wheel drive can be activated in manual or automatic mode. The ZIL-131 transfer case also has the ability to engage a lower gear with a coefficient of 2.08 when driving in particularly difficult conditions - loose snow, muddy soil, off-road conditions. At the same time, the torque transmitted by the transfer case to the wheel drives is doubled, which makes it possible not to overload the engine and transmission units when driving in difficult road conditions.

The transfer case is two-shaft with helical gears. The transfer case body is cast from cast iron. The box design includes a back and top cover.

If necessary, a power take-off (PTO) is mounted on the upper plane of the transfer case. It serves to supply power from the car engine to various units and devices that are part of special vehicles based on ZIL-131.

Appearance of the Zil-131 transfer case:

• on top there is a cover pressed to the body with 8 nuts, covering the seat for installing the com;
• in the center is the flange of the transfer case drive shaft;
• bottom right front drive axle drive flange ZIL-131;
• at the bottom left is the pneumatic front-wheel drive activation chamber;
• on the right, at the same level with the drive flange of the transfer case, the control rods for direct and low gears.

Transfer case ZIL-131, rear view:

• at the top left you can see the control rods for turning on forward and reduced speed;
• at the top right, a cover with eight nuts covers the connection flange of the ZIL-131 power take-off;
• at the bottom right is the parking brake drum, combined with a flange for mounting the rear axle drive cardan;
• On the left is the oil filler hole of the transfer case with a tetrahedral threaded plug.

A cross-sectional view of the ZIL-131 transfer case can be seen in the illustration.

Transfer case operating modes

There are several main modes.

Direct (second) gear activated

The mode is designed for driving a truck on paved roads.

The RK control lever is moved to the rear extreme position. In this case, the torque from the gearbox driveshaft through the flange (9) is transmitted practically without mechanical losses from the drive shaft (15) to the secondary shaft of the rear axle drive (22). All gears of the box rotate freely. The front axle is disabled.

On dangerous sections of the road, the driver can activate the front axle drive using an electric toggle switch (switch on the control panel in the cab). At the same time, the pneumatic solenoid valve will turn on, and compressed air will enter the pneumatic chamber (8), which will push the control rod forward. The rod, in turn, moves the front axle engagement fork (32) and through the drive (21) and driven (2) direct drive gears, the gear coupling carriage (35), the torque goes to the transfer case flange (6), then to the front drive truck. The lamp on the instrument panel will light up - the drive enable indicator.

Downshifting

When driving off-road, the driver moves the transfer case control lever to the extreme forward position. In this case, the rods from the lever act on the transmission mode switching rods. The upper control rod with its fork moves the carriage (18), disconnecting the drive shaft (15) and the rear axle drive shaft (22).

The lower rod fork moves the gear carriage (37), thereby combining gears (3) and (2). At the same time, the lower rod, by pressing the microswitch located inside the transfer case, supplies voltage to the pneumatic solenoid valve. He, in turn, uses compressed air using a pneumatic chamber (8) and a fork (32) to connect the front axle drive shaft (5) with a carriage (35). Thus, the torque from the ZIL-131 gearbox through the cardan and flange (9) will go to the transfer case input shaft (15), pass through the gears (17), (3), (2) and (21), and go to the drive output shaft rear axles (22). From the gear (2) through the gear carriage (35), the torque will be transmitted through the front axle drive shaft (5) to the flange (6).

History of creation and development

When developing the ZIL 131 car, weight and cross-country ability came to the fore. Nevertheless, the designers of the Likhachev plant successfully completed the task. The result is an inexpensive to manufacture, easy to maintain and highly unified military truck, much like its civilian counterpart under the 130 index.

It is worth noting that the version for the national economy was the first to go into production. And only three years later the army version was released. It was equipped with the appropriate components required for military specifications. However, after five years the vehicle began to be positioned as a simplified truck for civilian use. The classic 131 was mass-produced until 1986 for 20 years. Then an analogue with increased weight, the ZIL 131 N, was developed. In addition, this version received an improved engine, better efficiency parameters, a synthetic awning and modernized optics. However, this modification was not widely used, despite the fact that it was also produced at UAZ.

Transfer case operation

The front axle is engaged by an electro-pneumatic device. It consists of:

• Electric air valve;
• Pneumatic chambers;
• Two microswitches;
• Relay;
• Switch;
• Signal lamp;

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It is important to know that the transfer case in the ZIL 131 car will work normally if an electric air valve is installed on the frame cross member and a pneumatic chamber is attached to the front wall of the crankcase. The microswitch is located on the latch body and on the pneumatic chamber body, and the switch and warning light are located in the cabin, and under the hood there is a relay

Type of transfer case ZIL 131

When switching on occurs, the transfer case of the ZIL 131 car gradually puts all other mechanisms into operation. The driver moves the lever forward and immediately it rotates around the attachment point on the upper link and the lower end through the link. With the help of the rod and fork, the coupling moves back and at this moment the gears are connected to each other. When the rod moves, the microswitch immediately starts working, thanks to it the relay circuit is closed, which immediately closes the circuit on the electric air valve. The armature of the electromagnet moves downwards, the inlet valve opens and the outlet valve closes.

In order for the transfer case on the ZIL 131 machine to work fully, compressed air from the pneumatic system must enter the pneumatic chamber, and it must move the coupling back through the rod and at the same time connect it to the gear ring of the shaft. The drive shaft transmits torque through the gears, which is evenly distributed between the gear and the shaft, and then passes to the axles of the rear bogie and then through the clutch it passes to the drive shaft of the front axle.

When the shutdown occurs in first gear, the transfer case on the ZIL 131 machine operates as follows:

• The electromagnet circuit opens;
• The inlet valve closes tightly;
• The exhaust valve opens;
• The front axle is automatically switched off using a return spring.

To engage second gear, the transfer case on a ZIL 131 car operates as follows:

• The lever rotates around an attachment point on the lower link;
• The coupling moves backward through the rod, rod and fork, and at the same time all mechanisms are connected to the gear inner ring of the gear;
• From the drive shaft, due to the torque, the action passes directly to the drive shaft of the rear bogie axles.

If the movement occurs on a slippery road, then you need to engage the axle in forward gear, and the electromagnet circuit should be closed forcibly. To do this you need to use the switch. The torque will be transmitted directly through the gears and clutch directly to the drive shaft on the front axle.

In all other gears, if the front axle is engaged, then the torque will be distributed in direct proportion to the loads that fall on the rear bogie axle and the front axle.

When the front axle is turned on, the microswitch will automatically close the circuit, and a warning light will light up in the driver's cabin.

The transfer case on the ZIL 131 car is lubricated with a special sprayer. Oil (in this case, its brand is Tap-15v) is poured into the crankcase. The usual rate is 3.3 liters.

Diagram of transfer case suspension, control and control valve ZIL 131

Specifics of the work of the RCP

1. Second gear. Used when moving on concrete, asphalt and hard ground surfaces. The gearbox handle moves to the rear position, and the moment of force is transmitted from the cardan using an edge. Then it is sent to the secondary drive shaft of the rear axles. At the same time, all gears rotate in a free order, and the front-wheel drive throttle is deactivated. In case of movement on difficult road sections, the ZIL-131 front axle is activated from the electric drive located in the cabin. It activates the pneumatic electrovalve, and the air is sent to the pneumatic chamber, which is responsible for the activation rod. It moves the front-wheel drive activation fork. The moment of force at this time is supplied to the flange using the direct drive and driven gears and the drive clutch carriage. Next, it will be directed to the front drive of the car, and the drive activation indicator will turn on on the display.
2. Low gear. Used when driving the car on difficult road sections. The gearbox handle moves to the forward position, and the thrust from it acts on the rods that change gearbox gears. The upper rod fork moves the carriage and separates the shafts and drives of the rear axles. The lower rod fork moves the gear carriage and connects the gears. At this time, the lower rod, pressing the activation button located in the control gearbox and supplying a discharge to the pneumatic electric throttle, which compresses the air flows, activates the drive shaft of the ZIL-131 front axle with the carriage. It turns out that the moment of force is transmitted to the input shaft from the gearbox through the use of a cardan and an edge. It overcomes the gears and ends up on the output shaft of the rear axle drive. Along with this, the rotation speed of the output shafts is reduced by 2 times in comparison with the second gear, and the torque increases by the same amount. It must be emphasized that front-wheel drive is activated automatically when using a lower gear.
3. Neutral gear. The gearbox shift knob is located in the middle and helps to separate the shafts so that the moment of force flows from the input shaft and gear to the PTO drive. The car remains motionless.

In the absence of transmission fluids, the manual gearbox weighs about 115 kg. After filling this type of composition, the weight increases by an average of 2.5 kg. Summarizing the above, the connection diagram for the ZIL-131 front axle does not look complicated. Front-wheel drive is activated electrically from the passenger compartment, taking into account the fact that the manual transmission operates in first gear. If a reduction gear is used, the front axle is automatically activated.

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Full payment upon purchase

NOTE! In this case, the order is sent by any transport company. Partial prepayment. Part of the cost of the goods is paid, the rest of the amount is paid after the unit arrives at the terminal of the transport company in your city

NOTE! In this case, the order is sent exclusively by Business Lines.

IMPORTANT! In case of full or partial payment, we will send you by mail a copy of the issued delivery note, certified by a seal, indicating the name of the product and its cost. The original invoice will come with the goods

How does the gearbox of the ZIL 130 car work?

ZIL 130 and 131 cars are equipped with a three-way five-speed manual gearbox. The gearbox of this vehicle allows the driver to move forward at five speeds and backward at one. You can find a drawing of the device below. As can be seen in the diagram, the ZIL 130 and 131 gearbox is equipped with two inertial synchronizers, which include the second and third, as well as the fourth and fifth.

The drive shaft, together with the gear and ring gear to activate the fifth (direct) speed, is installed in the crankcase on bearings. In addition, a cylindrical roller bearing is mounted in the bore of the pulley itself, and the secondary pulley, in turn, rests on it. The intermediate shaft in the ZIL 130 and 131 box is mounted in the lower compartment of the crankcase. There is another gear installed on this shaft, which is in regular mesh with the input shaft (ID) disk. Here, the developers of models 130 and 131 decided to install wheels of second, third and fourth speeds.

Sectional diagram of the unit with all symbols

Identification of all transmission components

In addition, spur gears are mounted on the cardan, designed to activate reverse (reverse) gear and first gear. Also, activation of these modes is provided by a spur gear and synchronizer components mounted on the splines of the secondary pulley.

In addition, additional gears are mounted on the secondary shaft:

• to engage second gear;
• to activate the third mode;
• to turn on the fourth.

And these gear rings, when operating, are in constant engagement with the wheels mounted on the intermediate disk. The reverse movement unit is mounted on special roller bearings, which are located on an axis in the crankcase. Here they are installed quite securely. The reverse drive cardan also works in conjunction with the idler pulley through additional wheels.

As for the inside of the crankcase, the working fluid is poured here, so this part is always closed from debris and dust. The switching mechanism itself is installed here. It should be noted that the gearbox switching mechanism on ZIL 130 and 131 is designed in the same way as on GAZ 53.

Switching circuit

The switching diagram for the ZIL 130 and 131 gearboxes is presented below. In general, the scheme is original, but if you believe the words of ZILovodov, then you can get used to it very quickly.

How the transmission lever shifts

Features of the gearbox on ZIL-131

The ZIL-131 truck is a reliable vehicle that was produced by the Likhachev Moscow Automobile Plant. The vehicle has a high degree of cross-country ability. The total weight of the ZIL exceeds 10 tons. A traction winch can be installed.

Features of the engine and transmission system

The car is equipped with a V-shaped 8-cylinder engine (carburetor) that produces 150 horsepower. The machine is equipped with 3 drive axles, with the front axle having electro-pneumatic control.

The car is not economical in terms of fuel consumption, which is poured into the engine. The use of AI-76 is suitable, and it consumes about 40 liters per 100 km. The fuel consumption rate is affected by the conditions under which the ZIL travels.

In order to save fuel, instead of gasoline, the 131st model can be equipped with a diesel engine, the volume of which is 4.7 liters, with a power of 109 hp.

As for the gearbox on the ZIL 131, it is mechanical. It requires approximately 5 liters of transmission fluid. If there is a ZIL power take-off, more new fuel is required (about 6.5 liters).

The car has a transfer gearbox. It ensures stable movement of the ZIL vehicle at low speed, while the power plant operates with the highest torque.



You should fill in about 3.3 liters of new fuel, giving preference to all-season oil TSp-15K. The main feature of this liquid is its excellent low-temperature properties. The machine will not lose its functionality at negative temperatures (up to -20°C).

In addition to this, the working capacity will not decrease even at +100°C. It also provides protection against wear of gearbox components. If vehicles are often operated at temperatures above -20°C, it is recommended to use TSP-10 fuel.

The gearbox oil needs to be changed every 30,000 km.

Transfer gearbox composition

What is included in the transfer case for ZIL 131? According to the standard, the transfer case includes: shafts, crankcase, gears, couplings, rod, pneumatic chambers, valves, rods.

The gear shift diagram shows that in the crankcase there is a drive shaft with a gear and a ring gear on bearings. The last consumable item is designed to activate the fifth speed.

The installed crankcase is made of gray cast iron. There is a closed type system ventilation. 12

The valves are made of heat-resistant steel. Thanks to this, they can easily withstand the resulting loads.

Engaging the axle in forward gear is a necessary action when the vehicle is moving on icy conditions. If the front axle does not turn on, you need to check whether there is power to the switch and the condition of the valves.

There is a breather in the top cover, and a drain and control-fill hole in the rear cover. A pneumatic chamber is securely fixed on the front wall of the crankcase. Oil seals are found in shaft bearing caps.

In the inner part of the crankcase, the truck manufacturer installed a mechanism for switching speed modes.

Possible gearbox breakdowns

It is possible to determine whether the gearbox is broken or not by the characteristic sounds. Signs of trouble:

• the occurrence of loud noise;
• spontaneous activation of gears;
• oil leak.

If there is strong noise from the transfer case, it is advisable to check the condition of the gears and bearings. These elements must be replaced. When the teeth wear out, the driver may encounter problems such as spontaneous gear shifting.

You need to pay attention to the condition of the sealing elements. With prolonged use of the vehicle, they quickly lose their working properties. This is the reason why fluid will leak.

The membrane in the pneumatic chamber and fastenings must be checked.



Prevention of breakdowns with gearboxes

To avoid serious damage, vehicles should be diagnosed.

When changing gearbox oil, you should use fuel that matches the vehicle system. When the gearbox is drained, you need to clean the magnet that is on the plug.

Add new fluid to the inspection hole. The breather located on the crankcase hatch cover must be cleaned.

Thus, the ZIL 131 gearbox must be serviced periodically. This will be a guarantee that vehicles will not quickly lose their working properties.

Source: https://prokpp.ru/pro-korobku-peredach/na-zil-131.html

Transfer case for ZIL cars

TO

category:

Car chassis

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Transfer case for ZIL cars

On a three-axle ZIL-131 car with a drive on all axles, a two-stage transfer case is installed, attached behind the gearbox with four bolts to two longitudinal beams, supported through rubber cushions on the brackets of the transverse beams of the car frame.

The cast-iron transfer case housing has a detachable rear cover 9 and a hatch on top for connecting the power take-off box, closed with a lid on which the breather is located.

The back cover has oil filler and drain holes, closed with plugs.

Three shafts are mounted on bearings in the crankcase walls: the drive shaft, the front axle drive shaft and the rear drive axle drive shaft 16.

The drive shaft is installed at the rear end in the groove of the rear axle drive shaft on a cylindrical roller bearing, and at the front end in the crankcase wall on a ball bearing secured by a retaining ring and a cover with a self-clamping oil seal.

The rear universal joint flange is secured to the splines of the outer end of the shaft with a nut and washer. A dirt deflector is welded to the flange.

The drive shaft is connected to the end of the secondary shaft of the gearbox using an intermediate cardan shaft with two universal joints.

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The first gear gear is secured to the drive shaft on a key, and behind it, on the shaft splines, there is a sliding gear clutch for engaging the second (direct) gear, which can engage with the internal ring gear made in the drive shaft gear of the rear drive axles. The shaft is installed in the walls of the boss of the detachable crankcase cover: in front - on a cylindrical roller bearing, and in the rear - on a ball bearing. A speedometer drive worm is fixed between the bearings on the shaft, with which the driven gear is meshed, the shaft of which is installed in the socket and in the sleeve of the crankcase cover. The rear shaft bearing is secured with a retaining ring and closed with a cover in which a self-clamping oil seal is installed. The cover is a bracket for installing central brake pads.

Modifications

• ZIL-131 – basic modification;
• ZIL-131A is a version with unshielded electrical equipment, which it received from the ZIL-130. Its differences from the basic version were the absence of special military equipment, a middle bench in the body and a searchlight. Production of the car ended in 1971;
• ZIL-131V is a truck tractor built on the basis of the ZIL-131. The car had 2 spare wheels, a shortened frame and a fifth wheel coupling. The car was used to transport goods together with a semi-trailer weighing 12,000 kg (on dirt roads - 10,000 kg). Produced from 1968-1986;
• ZIL-131D – experimental chassis for dump trucks; did not go into mass production due to many shortcomings;
• ZIL-131D is a model with the same name and a Caterpillar engine, created in 1992. Its production lasted 2 years;
• ZIL-131N is a modernized version of the basic model. The main differences: a new ZIL-5081 engine, an increased service life (250 thousand km), an awning made of synthetic material and improved optics. Production of the ZIL-131N ended in 1987;
• ZIL-131NA – analogue of ZIL-131N with unshielded electrical equipment;
• ZIL-131NV - truck tractor with an improved platform;
• ZIL-131N1 – modification with a 105-horsepower diesel unit “D-245.20”;
• ZIL-131N2 – version with a 132-horsepower diesel unit “ZIL-0550”;
• ZIL-131S and ZIL-131AS are northern versions. These models were equipped with a cabin with an autonomous heater, frost-resistant rubber products, additional thermal insulation, fog lights, battery insulation and double glass. Cars were used in temperatures down to -60 degrees;
• ZIL-131NS, ZIL-131NAS and ZIL-131NVS - improved versions in the northern version;
• ZIL-131X - model for desert and hot areas;
• ZIL-131-137B – road train;
• ZIL-131 KUNG (unified body of zero dimensions) - an insulated building with a stove and an air purification station (FVUA-100N-12) can serve a wide range of military needs.
• ZIL-131-ATZ-3 – fuel tanker;
• ZIL-131-MZ-131 – oil dispenser;
• ZIL-131-ATs-40 – fire engine.

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Axle adjustment

Since ZIL-131 gearboxes have a unified design, the adjustment of the units is the same for all axes. Tuning refers to checking and adjusting the bearing preload, as well as ensuring correct contact of the bevel gear. It should be remembered that the 2-row bearing of the drive shaft of the cylindrical transmission cannot be adjusted. Replacement of elements of the support assembly is unacceptable; in case of wear, it is replaced as an assembly.

To adjust the bearings, you must:

1. Disconnect the propeller shaft from the gearbox flange.
2. Disassemble the assembly and remove the cup assembly with the drive gear bearings. For this purpose, auxiliary bolts are used.
3. Install the adjusting shims from the kit between the end surfaces of the inner rings of the bearings. Installation of only 2 gaskets is allowed.

Bevel gears are selected at the factory based on the contact patch and the gap between the meshed teeth. The parts undergo grinding and receive an individual stamp. If 1 part breaks, the entire set must be replaced. The contact patch is adjusted using spacer washers, which are placed under the flange of the bearing housing of the drive axle. The shape of the contact patch is determined by the paint that is applied to the teeth. If necessary, gaskets are also installed in the bearing sockets of the driven shaft.

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When the wheel bearings are properly tightened, the wheel rotates by hand without jamming or visible axial runout. Tightening is performed with the axle flange cover removed. Underneath there is an adjusting nut, which is secured with a lock washer. The condition of the bearings in the support cams is checked after the vehicle is installed on the trestles. Wear is corrected using shims placed in the supports. The maintenance procedure depends on the accuracy class of the installed bearings.

Scheme

Transfer cases for ZIL 131 cars are manufactured according to the following schemes:

• With differential drive;
• With locked drive;
• With mixed drive.

Each assembly option has its own characteristics. The transfer case of the second type ensures synchronous rotation of all axles. Thanks to this scheme, torques are distributed evenly to the resistance force.

Transfer case ZIL 131

In transfer cases where the drive is made differential, the torque passes through the differential. Thanks to this scheme, the output shafts rotate at different angular speeds. This differential has another name - center differential.

In transfer cases where the drive is mixed, half of the driven shafts have the same angular velocity, and the other is connected using a differential. The “mixed” type also includes boxes with locking differentials.

From this classification we can conclude that the power flow from the main transfer case is distributed to:

• One front and one or two rear axles of cars;
• Two front axles and two rear axles;
• On the drive wheels of the left or right side of cars.

The conclusion is as follows. Transfer cases for the ZIL 131 car are:

1. Interwheel;
2. Intercarriage;
3. Inter-sided.

Structural characteristics of RKP ZIL-131

With the help of manual transmission, the moment of force extracted from the gearbox is transformed and directed to the drives: front and rear, and directly to the wheel axles. The front axle is activated both manually and automatically. The manual transmission may also include a low gear with a value of 2.8, which is intended for movement in particularly difficult natural conditions, for example, off-road. At this time, the moment of force transmitted to the wheel axles increases by 2 times. This allows you to not put too much stress on the engine and transmission.

Fire trucks ZIL 131

Serial production of PAs based on the ZIL 131 occurred in 1970-1984, when models 137 and 137A were developed. They turned out to be successful in combining an all-wheel drive chassis with absolute unpretentiousness to operating conditions. In terms of performance characteristics, the ZIL 131 fire truck differs from the ZIL 130, but it could not completely replace it. To extinguish fires, it can be filled with water or foam. The water tank is designed for 2.4 tons, and the foam tank is slightly smaller compared to the model discussed above, 150 liters. Moreover, the total curb weight of this car is 11 tons. Load distribution on the front axle is 2980 kg, on the rear axle – 8170 kg.

The A-76 gasoline carburetor engine of the ZIL 131 ATs-137 and 137A has a power of 150 hp. or 110 kW. When fully loaded, the car reaches a speed of 80 km/h with a fuel consumption of 40 liters per 100 km. The wheelbase includes six driving single wheels. Thanks to all-wheel drive, the car copes with off-road conditions. This is an important indicator for preserving the machine stock of this modification as the main technical unit of the Ministry of Emergency Situations.

The advantage of PA based on ZIL 131 is the water heating system located in the tank. It operates on the energy of exhaust gases. Also a distinctive feature of this modification is an improved two-row cabin with protective bars on the windows in case of riots.

Performance characteristics of the ZIL 131 ATs-40-137A fire truck

Pump	PN-40UV
Pump type	Single stage centrifugal
Water supply (l/sec)	40
Suction height, max, m	7
Reference suction height, m	3.5
Foam mixer	PS-5
Foam mixer type	Water jet ejector
Foam mixer capacity at low expansion rate, m3	25
Foam mixer productivity at average expansion rate, m3	250
Fire monitor	SLK-P20
Water consumption for the trunk, l/sec	19
Foam ratio at the exit of the barrel	6
Water jet range, m	60
Foam jet range, m	50
Rotating the fire monitor	+90… -20° vertical
Extinguishing area with low expansion foams at Itr = 0.1…0.15 l/(s*m2)	41,67…27,78
Extinguishing area with low expansion foams at Itr = 0.05...0.08 l/(s*m2)	83,33…52,08
Length of pressure hoses, m	408
Dimensions (l*w*h), mm	7640*2500*2950

Important Electric cultivator Lux 1400 for earthworks

Despite its popularity, the PA based on the ZIL 131 has some disadvantages. For example, the principle of fastening to the frame, which is why the geometry of the tank is often violated, and as a result - its depressurization.

The peak of production of fire trucks based on ZIL trucks occurred in the 1970s, but the popularity of this equipment does not subside even today. Its advantage is its ease of use and the ability to work both in urban areas and in off-road conditions.

Main features of the power unit and transmission of the ZIL-131

ZIL-131 is a domestic three-axle off-road truck. It was produced by the Likhachev plant from 1966 to 2002. The bulk of the vehicles produced were for army needs. The car contained many useful and progressive technical solutions for that time.

Operating order of ZIL-131 cylinders

The truck used a carburetor V-shaped eight-cylinder engine with ignition based on an electronic switch.

The engine camshaft and ignition system provide the following order of operation of the ZIL-131 cylinders: 1-5-4-2-6-3-7-8. Engine power output is at least 150 hp at 3200 rpm.

ZIL-131 gearbox shift diagram

The car uses a five-speed manual gearbox (Gearbox).

At all gearbox speeds except first gear and reverse gear, they have synchronizers. The ZIL-131 gears are switched using a lever located on the top cover of the gearbox.

Transmission ratios:

• first – 7.44;
• second – 4.10;
• third – 2.29;
• fourth – 1.47;
• fifth – 1.00;
• reverse gear - 7.09.

The first gear of the box is used only when starting to move in off-road conditions and is located on the same “shoulder” with reverse gear. This was done to “rock” a car stuck in mud or loose snow by quickly alternating first gear and reverse gear.

The ZIL-131 gearbox switching diagram is presented below.

The dry weight of the ZIL-131 gearbox is about 100 kg.

Clutch

The ZIL-131 clutch is single-disk, dry, sealed, and works reliably in fording conditions. The drive for disengaging and engaging the clutch is mechanical, lever driven from the driver’s pedal in the cabin.

The gearbox in the ZIL-131 transmission transmits the power flow through the driveshaft to the transfer case (TC) or in professional slang “transfer case”.

Robot protection

The driven spur gear is a ring gear that is attached to the differential cups.

When the main gear is operating, the torque changes in both pairs of gears in magnitude, and in the bevel pair, in addition, in direction.

The main gear is lubricated by splashing; there are channels in the crankcase walls for oil to pass to the bearings. 5 liters of oil are poured into the main gear housings of all axles.

Adjustment of the tapered bearings of the drive bevel gear shaft is carried out when axial play appears in them and is carried out by selecting adjusting washers of the required thickness located between the inner rings of the bearings. Correct adjustment is checked by the force required to rotate the shaft in the bearings. This force, determined using a dynamometer attached to the shaft flange, should be in the range of 1.3-2.7 kgf.

The double-row bevel bearing of the drive cylindrical gear is installed with a selected adjusting ring and does not require additional adjustment.

The lateral clearance between the teeth of the bevel gears should be 0.15-0.45 mm at the wide part of the tooth, which corresponds to a rotation of the input shaft flange by 0.18-0.54 mm when measured at the radius of the bolt holes and with the driven gear stationary . The specified gap is adjusted by moving the drive and driven gears by changing the number of shims.

The correct engagement of the bevel gears is checked using paint on the contact patch.

The differentials of the ZIL-131 car are gear-type, conical, installed in the axle gearbox housings on two bearings each. The differentials of all three axles are identical in design and differ from the differential of the GAE-53A car only in the size and shape of the parts.

The axle shafts of the ZIL-131 car are flanged, completely unloaded, and the design and fastening are the same as those of the GAZ-66 car. Each axle shaft is sealed with an oil seal located in the flange of the bridge beam.

Ball joints of equal angular velocities are similar in design and operation to the joints of the GAZ-66 car. The only difference is that the central ball does not have a finger. Each joint contains 1.3 kg of AM grease.

Read more: Drive axle mechanisms of the ZIL-130 car

TO

Category: — Car device

Device

The ZIL 131 car has a two-stage transfer case. The front axle has an electro-pneumatic connection. In first gear the gear ratio is 2.08, and in second gear it is 1.0. The box is attached using rubber pads and four bolts, which are also attached with rubber pads to the frame cross member brackets.

ZIL 131 transfer case control diagram

In general, the transfer case on a ZIL 131 car consists of:

1. Pneumatic chambers;
2. Signal lamp;
3. Switches;
4. Rod;
5. Locking device;
6. Retainer housings;
7. Drive shaft;
8. First gear gear;
9. Rear bogie drive shaft gears;
10. Rear bogie drive shaft;
11. Second gear clutches;
12. Front axle drive shaft;
13. Gear shaft;
14. Crankcase covers;
15. Front axle clutches;
16. Second gear gears;
17. Carter;
18. Rod;
19. Traction;
20. Lever;
21. Electro-pneumatic valve;
22. Switch;
23. Relay;
24. Inlet valve;
25. Exhaust valve;
26. Control and filler plugs;
27. Drain plugs.

The main parts include the following: crankcase with covers, input shaft with gear, clutch with bearings, front axle drive shaft along with gears and couplings. No less important is the mechanism for shifting gears and controlling the engagement of the front axle.

The box housing itself is made of cast iron, it is detachable, the back part is closed with a lid. The top hatch is also closed with a lid and a power take-off is installed on it. The top cover is equipped with a breather. The drain hole and control filler hole are located on the back cover, and there is a magnet on the drain plug. The shaft exits from the crankcase are thoroughly sealed. An oil washer is attached to the front axle shaft.

Bridge repair

During operation of the truck, oil should be periodically added to the crankcase and replaced with a new one (according to the service card). There is a grease nipple in the steering knuckle housing. Lubricant is filled until the substance appears from the control hole on the bottom of the support. After this, the hole is closed with a protective plug. When replacing lubricant, parts must be washed.

Repair of the drive axle is carried out in case of breakage or excessive wear of gears or bearings, as well as steering knuckles and hinges. When assembling the ZIL rear axle, it is necessary to ensure the required tightening force for the nuts. A similar requirement applies to other transmission components.

In this case, it is important not to overtighten the threaded connections, since the bolts may break or the threads cut inside the crankcases may break.

In case of severe damage, it is recommended to install a new unit. The price of the front axle without mileage is about 25 thousand rubles. Used units removed from disassembled trucks are estimated at 10-14 thousand rubles.

Repair of transfer case ZIL-131

Transfer case ZIL-131 is a reliable and durable unit. However, if signs of improper operation of the gearbox appear - increased noise, grinding noise when switching modes, “knocking out” speeds, lubricant leakage, the gearbox should be removed from the car.

Then, at the repair site, the box is disassembled and examined. Faulty parts and assemblies are replaced with new ones. Then the box is assembled and installed on the truck. After adding fresh lubricant, make a test drive and determine the serviceability of the repaired transfer case.

Cabin and body

The cabin of the truck in question is of an all-metal configuration, with three seats and additional thermal insulation. The unit is heated using a liquid method, from the motor cooling system with a centrifugal fan. The heater is controlled using a special damper on the cab panel. Ventilation is provided by roll-down windows, rotating windows and a channel in the right wing mudguard. The seats inside are separate, the driver's seat is adjustable, the cushions are made of a sponge rubber compound.

The body of the ZIL 131 car is a wooden platform with a metal edging and transverse base beams. Of all the sides, only the rear element is folding. The cargo platform is designed to transport people. The side compartments have folding benches for 16 seats. In addition, there is an additional eight-seater bench located in the middle part of the body. The protective awning is installed on removable arches.

Description

The weight of the ZIL 131 allows the vehicle to be classified as a truck with all-wheel drive and a front-mounted engine with a 6x6 wheel formula. The truck was originally designed as an off-road vehicle. Its task is to transport goods and people, tow trailers on any kind of soil. In the model line, this car replaced the obsolete predecessor ZIL 157.

In terms of cross-country ability, the vehicle is not inferior to many tracked competitors. The updated truck has been significantly modernized compared to its predecessor. It received an improved axle, tires with 8 layers and a special tread pattern, front-wheel drive became switchable, and a single driveshaft was installed on the transfer mechanism. The car performed excellently in difficult road and climatic conditions, operating stably and reliably in temperatures ranging from – 45 to + 55 °C.

Problems and solutions

Very often, a breakdown of the transfer case can be foreseen; to do this, you should only inspect the car before leaving the track and listen to the sounds occurring during operation of the mechanisms.

The following problems are possible:

1. Loud noise in the transfer case. This is an indication that some parts are damaged: gears or bearings. In this case, the transfer case is disassembled and the failed parts are replaced;
2. The gears turn off on their own, involuntarily. Most likely, the teeth of the carriages or the small ring gears on the wheels are worn out. Such a breakdown is possible when the gear shift forks are worn out. Damaged parts need to be replaced;
3. Oil is leaking and the membrane is broken. If it is found that oil is leaking through the sealing collars, then you need to carefully inspect them. If, upon inspection, signs of wear are found on the edges, they must be replaced. If the membrane in the pneumatic chamber is broken, then it also needs to be changed;
4. The control rod adjustment is broken and the pins in the rod forks are worn out. In such a situation, the thrust should be adjusted again and the fingers changed.

Maintenance of RKP ZIL-131

Maintenance of the control gear takes place in several main stages:

• Regular maintenance, which consists of pre-trip inspections of the vehicle and the coating under the engine and other major mechanisms for fluid leaks.
• Maintenance, which includes inspections of the control gear for stability of fastening and cleaning of the breather.
• CO, which consists of seasonal replacement of fluids and oils in the gearbox. Draining is done through the drain valve, and filling is done through the appropriate technical opening.