ZIL-5301 Bull. Pneumatic brake actuator

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Owner reviews: All-wheel drive and high ground clearance

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Problems with brakes. | Topic author: Jereck

Good day to all. Just the other day I became the owner of a ZIL 5301 1999 - you can’t say it’s alive, but it’s tolerable.

Evgeny (Stela) encountered something similar on a gazelle - replacing the main one solved everything. It’s not worth taking a repair kit - r.. rare. Better get a new one. It's really expensive. When you remove the sorcerer correctly, he turns off the rear brakes on an empty car. In general, in theory, look at how the rod on the brake chamber moves (the one on which the turbocharger hangs). Maybe there's something sticking there.

Konstantin (Jenkin) Thanks bro.

Alexey (Rosalynd) most likely the front calipers are sticking, lubricate the pistons with graphite lubricant

Konstantin (Jenkin) It's the butt that bites!

Evgeny (Stela) what helped?

Konstantin (Jenkin) No, it didn’t work out - I bought a repair kit due to poverty. I'll try installing a new one, I just need to tweak it a little))) Thank you!

Konstantin (Jenkin) Hooray, there are brakes. I went through everything new, developed the cylinders and it worked. Thank you all for your participation, it wouldn’t have been possible without you. There is another problem, the brake pipes had to be plugged in some places, because... as a result of my labors, they were simply broken off. It’s impossible to find it on the Internet, has anyone found something similar?

Kostya (Vasanta) 4 months ago rebuilt the brakes, installed the main brakes on the UAZ Patriot with separated barrels, so far there are no problems with them and the price for them is 1200 rubles per piece. and safer. If anyone is interested, write.

Roma (Habimana) Why does the air not reach the rear brakes, the rod on the camera does not move and one of the receivers is EMPTY!! (closer to the front)

Zheka (Laisha) AAAA, the rear brakes are a pain in our car, I first separated the front and rear separately, the next stage was replacing the GTZ, I installed it from a gazelle, with the help of a file it fits onto our brake chambers like a native one, then I threw out the sprockets, so they bullied me , a minimum of alterations and voila, the gazelle eccentrics fell into place like family, I’ll post a photo this evening, I’ve just disassembled the rear hub, I’m going far at the end of the week, I need to check the lubrication.

Alexander (Wynn) The rear practically does not slow down, in winter the current is on the skid

Roma (Habimana) Kostya, the main worker installed it from the UAZ.

Roma (Habimana) Zheka, where are the photos? )

Zheka (Laisha) Roman, I gave up hydraulics and installed 2pts4 brakes in May

Zil-5301Bychok installation of the brake system from GAZ-3310 Valdai

Zil-5301Bychok installation of the brake system from GAZ-3310 Valdai

hitek » Sep 29, 2015 10:01 pm

Hello Dear experts and forum visitors!

As you know, the bull car suffers from many congenital diseases, including a “weak” rear axle, rims of “wrong” design and useless brakes. Because By now we managed to sell the car, we did not have time to solve these problems. But the work remains, it’s a shame to throw it away, so I want to share it

And so, on the rear axle, it was planned to completely install the rear axle from Valdai, on GAZ-3307 springs along with brackets and springs from GAZelle. The procedure is not complicated and is described in detail on the Internet. It looks something like this:

Taken from here https://wroom.ru/index.php?id=forumtopic&topic=6244&page=24#f_head, https://wroom.ru/index.php?id=forumtopic&topic=9268&page=3

The front axle is more difficult. If you leave the original axle, you will get wheels with different landing sizes, and different types of brake system drive along the contours (pneumatic at the rear and hydro-pneumatic at the front). It will not be possible to install the Valdaevsky Bridge assembled due to serious design differences. Having collected the dimensions and calculated the dimensional chains, the following option was drawn: hubs, brake discs, and calipers from Valdai are installed on the reinforced beam and steering knuckles (under larger bearings) of the Bychka. The internal bearing remains Bychkovsky (the outer diameters are the same), the outer ones are the same. The following modifications will be required: - it is necessary to reduce the height of the ring under the oil seal by 10.5 mm - it may be necessary to additionally machine the fit under the ring (the internal bearing will sit deeper) - it is necessary to make a transitional stepped (step approximately 8 mm) faceplate for attaching the Valdaevsky caliper to the Bychkovsky fist - it may take a little modify the hub where the oil seal is installed. -spacer bushings are needed to install the oil seal.

The only thing is that I couldn’t find the Valdaevsky caliper to estimate the dimensions of the faceplate. Therefore, if someone decides to make such a change, this is the first thing to start with. (There are similar modifications online, with the installation of assembled Valdayev fists on a modified Bychkov beam - the brake chambers do not reach the springs)

And now, photographic materials: “Reinforced” steering knuckle Bychka

,

Valdai's fist, the caliper mount is clearly visible

Re: Zil-5301Bychok installation of the brake system from GAZ-3310 Va

hitek » Sep 29, 2015 10:03 pm

Source

ZIL MMZ-4502 LNG DUMP TRUCK | Topic author: 65115

people I want to install a D-245 engine on a ZIL, is it worth installing or what? #diesel

Andrey (Hamayoun) bet it, you won’t regret it. Will you bet it yourself or a company?

Andrey (Hamayoun) And there is a minimum of alterations.

Andrey (Hamayoun) If the engine is from a bull or from Valdai, then it’s a fairy tale.

Sergey (Kacie) Install. Power and fuel economy. Don’t forget mud tires with a winch, just in case.

65115 (Penwyn) we have a ZIL 131 dump truck with a winch

65115 (Penwyn) I think we can handle it ourselves, or is it that difficult?

65115 (Penwyn) from a steer and take it, or from a bison maz

Andrey (Hamayoun) there is nothing complicated. The mounts from the bull engine are one-on-one with the engine. You won’t have to tinker with the hydraulic system much, and then only with the reservoir.

65115 (Penwyn) now we need to raise money to buy the engine. gasoline is no longer profitable; gas was supplied and now it’s 20 rubles per liter

Andrey (Hamayoun) advice is free. Look for a bull, prices for them have dropped dramatically. A week ago a neighbor sold a bull for 75,000.

65115 (Penwyn) we also have a working engine for 50,000

Andrey (Hamayoun) with the box together?

65115 (Penwyn) no

65115 (Penwyn) they put the Zilov box in?

Andrey (Hamayoun) Well, yes, only the input shaft needs to be cut.

65115 (Penwyn) there is also a d-645 engine with a gearbox for 60 thousand, it was removed from a working car but they say it is capricious

Andrey (Hamayoun) has never met anyone like this, so I can’t say anything.

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How to install a UAZ GTZ on a ZIL bull: comments

I think you are making a mistake. I can defend my position. Write to me in PM, let's discuss.

History of the creation of ZIL 5301 Bychok

In 1992, work began at the Likhachev plant to create a small-sized and medium-tonnage truck. The main goal in creating the truck was to replace the existing medium-tonnage model range with more compact trucks.

Also in the early 90s , a large decline in ZiL products was noticeable, as new medium-tonnage trucks from Mercedes-Benz and Volkswagen entered the automotive market, which had small dimensions, good technical characteristics and load capacity.

In 1994, the first prototypes were manufactured, which had a chassis from the Mercedes-Benz T2 and many parts from previous ZIL models. After the release of the prototypes, testing began immediately. After successful completion of the tests, a small batch of prototype ZIL-5301 trucks was produced in 1995.

In 1996, ZIL engineers created a new design for the chassis and body, which made it possible to create many modifications and expand the scope of use of the 5301 model. After which mass serial production was established, which until 2011 was carried out at the Likhachev plant, and from 2011 to 2014 at the Petrovsky Auto Parts Plant.

Extended frame ZIL-5301

ZIL-5301 has relatively large design parameters, which contributed to the development of many modifications to expand the scope of application of this vehicle. The truck uses a ladder-type frame with channel side members.

This type of frame has a simple and safe design. The frame width is 84.5 cm, the shelves are 7 cm wide, and the thickness is 0.5 cm. There is a towing hole at the rear of the frame.

Engine MMZ D - 245.9 136 hp.

ZIL-5301 is equipped with a powerful four-cylinder diesel engine with a volume of 4.7 liters. In general, during the entire production of the model, many engines were installed on the truck, with different power levels, from 105 to 190 hp.

Since 2008, the main type MMZ D was adopted - 245.9 136 hp. Euro-3 standard. This unit has good characteristics, the main advantage of which is the high rotation speed of 2400 rpm and high torque of 460 N*m.

Five-speed gearbox ZIL-5301

"Bull" has a manual five-speed gearbox. The main gear in the transmission is hypoid. A gear synchronizer is also installed, which works in 2,4,5 and reverse gears. A standard Zilov clutch is used, which greatly simplifies the operation process. To control the brakes, the ZIL 5301 Bychok pneumatic system is responsible.

ZIL-5301. Design features of a single safety valve

A single safety valve (Fig. 1) serves to protect the vehicle’s brake drive from loss of compressed air in the event of damage to connecting lines and compressed air consumers not related to the brake system. When the pressure in a pneumatic drive (for example, a pneumatic-hydraulic clutch drive booster as a result of a violation of its tightness) decreases to a certain value, the safety valve disconnects the brake system of the vehicle and consumers.

To disassemble the valve

place it in a vice with soft jaws and clamp it by the body 8.

Remove the protective cap 4 and unscrew the adjusting screw 5, loosening the spring 2.

Unscrew screws b, holding cover 3 with your hand, and remove it together with spring 2 and membrane 7.

After disassembling the parts of the single safety valve, they must be washed with clean gasoline or acetone, dried and carefully inspected.

The surface of body parts must not contain cracks, hairs or other defects visible to the eye. Parts must be cleaned of rust and burnt marks. All rubber parts must be replaced.

Before assembling, the valve parts must be lubricated by hand with a thin layer of lubricant CIATIM-221, GOST 9433-60. The valve is reassembled in the reverse order.

Assembly

valves, rubber O-rings and other rubber parts must be done carefully to avoid damaging them. The presence of scratches, cuts and other defects on the surface of these parts is not allowed.

When assembling, screw the adjusting screw 5 into the cover to a depth of 14 mm from the surface of the end of the cover and, if using a new spring 2, keep the valve in this loaded position for 12...24 hours.

To adjust the valve, place it on a test bench and connect it according to the diagram shown in Fig. 1a.

Apply air under a pressure of 0.55 MPa to terminal I and gradually unscrew screw 5 until pressure appears in terminal II. Apply and release air three times at a pressure of 0.75 MPa into terminal I.

Gradually increase the pressure in port I. When the pressure in port I reaches 0.53. 0.55 MPa, pressure should appear in port II, and with a further increase in pressure in port I, the pressure in port II should be equal to the pressure in port 1. If necessary, adjust the valve.

When adjusting screw 5 is screwed into the cover, the bypass pressure increases, and when unscrewed, it decreases. After adjustment, the screw must be secured with paint. Check the valve for leaks. When washing, the appearance of air bubbles is not allowed for 1 minute.

Brake system

The brake system of the ZIL-5301 has a dual-circuit braking system, each circuit operates independently of each other. Braking is carried out by contours, in particular using one front and rear wheel with a cross-over system.

Front disc brakes on ZIL Bychok

The ZIL Bychok has air brakes with a hydraulic drive. The air pressure in the pneumatic system must be at least 7.2 atmospheres.

Brake system ZIL 5301 Bychok, diagram

The ZIL5301 air system increases vehicle safety in emergency situations. The brake design combines front disc and rear drum. In later ZIL Bychok models, the brake system has an anti-lock wheel device, which also increases the safety of the vehicle.

Cabin 5301, despite the fact that it does not have a very attractive appearance, has a high degree of safety. In general, it is a frame structure, which is covered with metal sheets. The interior and dashboard design is similar to previous models. The sheathing materials used inside the cabin are the cheapest, which reduces the cost of operation.

How to bleed the brakes

First you need to get convenient access to the brake system bleeder fittings. To do this, you can put the car on a lift or platform and remove all the wheels. Don’t forget to clean the fittings near each wheel from dirt and pour a little “brake fluid” into the prepared container.

Instructions:

1. Pour new brake fluid into the master cylinder reservoir.
2. Connect the hose to the fitting, and lower the other end into a container with brake fluid.
3. Command your assistant to press the pedal several times and hold it depressed until the fluid flows.
4. Unscrew the fitting and the liquid will flow into the container you prepared. Carefully monitor the fluid level in the tank and add as necessary.
5. Repeat the previous 2 steps until the brake fluid comes out clean without air bubbles, and tighten the fitting.
6. Repeat the same procedure on the remaining wheels.

Modifications

ZIL-5301AO

• Length in mm -3750 (cabin)
• Width in mm - 2254
• Height in mm -2365
• Weight in kg -3695
• Load capacity in kg -3000
• Wheelbase (total) -3650
• Ground clearance in mm -180
• Wheelbase front/rear -1690/1832
• Permissible load on the front/rear axle in kg - 1900/1995
• Power in hp -108
• Transmission - 5 speed mechanical
• Maximum speed in km/h - 95
• Fuel tank volume in l - 125
• Fuel consumption per 100 km in l -16

Owner reviews about ZIL-5310 “Bychok”

valera163valera:

I took the “bull” a year ago, the car was built in 1997... I drove it for a year, I’m happy with the car. Of course, the car requires care, like any other. In order not to freeze in winter, I insulated the cabin. I agree about the brakes - they are weak, but if you try it yourself, the ZIL 5310 brakes will be normal. I missed the cuff on the steering bipod. I bought about 5 repair kits, of which only one turned out to be “high-quality”. Shock absorber pins often break; I haven’t found a quality one yet.

I only changed the high pressure pipe in the engine. no need to skimp on spare parts. so that the axles, axle shafts, and gearbox do not fly, there is no need to overload, this is not a five-ton truck. I travel 60-70 km. at one o'clock. I traveled to Moscow, Tula, Ulyanovsk, Ufa and a lot around Russia and it never let me down. if you drive 90-100 km. per hour, like some, you will have to constantly repair the car, this is a Russian truck, not a Ferrari.

One of the positive aspects is that the ZIL 5301 has an air brake system. I can't stand hydraulic ones.

requires constant syringing. I use semi-synthetic oil and it starts perfectly in winter. If you listen to how gazelles and all sorts of “Chinese” “roll around”, then the “bull” is a wonderful car in comparison with them. if the owner himself drives the bull, the car will earn money; if the driver drives it, then in a couple of months it will be possible to sell it.