Assembly and installation of the ZIL-5301 gearbox
Assembly and installation of the intermediate shaft
Install key 8 in the shaft grooves and sequentially press the second gear pinion (0.005-0.055 mm interference), reverse gear (fit from 0.04 mm interference to 0.01 mm clearance), third and fourth gear pinions (0.015-0.065 mm interference), pre-selected by journals, onto the shaft.
The ZIL-5301 vehicle with division along the sides uses a flangeless two-cavity brake chamber, designed to act on the master brake cylinder and installed together with it on a bracket on the front panel of the cabin under the hood of the vehicle
Replacing the fine fuel filter
The service life of the fine fuel filter depends on the purity of the fuel used
ZIL-5301 Centrifugal Oil Filter
The design of the centrifugal oil filter is shown in Fig. 1
On the ZIL-5301, in addition to the voltage regulator relay, which is located to the left of the driver's seat below, there is also an excitation winding relay
The steering gear must be delivered to the work site where the disassembly and repair of the steering gear will be performed only after it has been thoroughly cleaned of dirt and washed on the outside with kerosene or another degreasing liquid.
Table of possible faults ZIL - 5301 with engine D 245 E3
Troubleshooting algorithm (Remedy)
Problems starting the engine
Engine fault codes D-245.7E3, D-245.9E3, D-245.30E3, D-245.35E3
Code table
Blink code (P-code) Type of malfunction Description of the malfunction Method and method of troubleshooting
Improving the control of the gas pedal ZIL-5301
Structurally, the gas pedal on the ZIL-5301 is very rigid.
The pedal is controlled by rods.
All parts of the boost corrector (BC) to be assembled must be clean, and the rubbing surfaces must be lubricated with engine oil
Wiping parts with a wiping material is not allowed.
Reinforced version of the ZIL-5301 clutch
Since April 2001, a reinforced version of the clutch has been installed on vehicles.
The damper part of the driven disk has been reinforced: the damper springs are vulcanized with rubber and look like a rubber cylinder
During major repairs, diesel engines must undergo cold and hot running-in, acceptance testing, technical inspection, and organoleptic testing
Usually vibration on ZIL-5301 is felt most at a speed of 60-70 km/h
If vibration occurs when driving ZIL-5301:
Bleeding air from the ZIL-5301 clutch control system
The hydraulic system of the clutch control mechanism consists of a master cylinder, an actuator cylinder with a pneumatic booster, a flexible hose and a pipeline
When repairing, the front axle beam must be checked for bending and twisting on a device (Fig. 1), which is installed on the spring platform
Adjusting the ZIL-5301 Parking Brake
The ZIL-5301 vehicles and AMO ZIL buses are equipped with a parking brake system driven by a spring energy accumulator (Fig. 1)
Possible malfunctions of the clutch and its drive ZIL-5301
Symptom / Cause of malfunction / Remedy
Clutch slippage, torque is not transmitted from the engine to the transmission:
Before assembly, wash the main gear and differential parts in the cleaning solution MS 6, MS 8 TU 6-15-978-76, blow with compressed air, check for compliance with technical requirements
Master brake cylinder of the drive, divided by axles
Removal and inspection of springs of the ZIL-5301 vehicle
Dismantling the front and rear springs is carried out in the same sequence