In detail: do-it-yourself repair of a psu zil goby from a real master for the site my.housecope.com.
Disassembly of the pneumohydraulic booster (PGU) for repair is carried out, as a rule, in the following cases: fluid flow through the cuffs 29, 33, due to their swelling when using low-quality fluids; when the cuff of the pneumatic piston 23 is worn. The probability of failure of other parts is small
1. Remove the cover 36 with the pusher 37 from the CCGT unit.
2. Fasten the CCGT in a vice, pointing up the front housing 26. Unscrew the connecting bolts 12 (2 pcs.), 19 and 25 (5 pcs.). The last to unscrew the bolt 19 located in the area of the gearbox. In this case, you should hold the body 26, as springs 11 and 22 act on it. Remove the body 26, the springs 11 and 22, the diaphragm 10 assembled with the seat.
3. Using a special wrench (Fig. ↑), unscrew the housing of the follower piston of the gearbox 4 from the rear housing 1 (see Fig. 1).
4. Remove the rear housing 1 of the amplifier from the vice.
5. Remove the circlip 35 and remove the clutch release piston 34 assembly from the rear housing, pushing it out of the protruding rod from the side of the seal 2.
6. Remove spacer sleeve 30, spring 31, sleeve 32 and collar 33 from piston rod 34.
7. Remove the retaining ring 21 of the clutch release piston rod seal and the washer 28.
8. Press out the collar 29 and seal 2 of the clutch release piston rod from the rear housing.
9. Remove rubber rings 1 and 3 from the piston seal housing 2.
10. On the body 1 (see Fig. 1), unscrew and remove the bypass valve 5 assembled with a cap. Unscrew the screws 9 securing the cover 8 of the outlet, remove the cover and the seal 7 of the outlet.
Video (click to play).
The last two operations are optional.
To disassemble the diaphragm of the amplifier reducer, it is necessary to unlock the nut 3 of the reducer diaphragm and unscrew it. Remove washer 2, diaphragm 1, washer 6 and gasket 5 from the seat 4 of the diaphragm. This assembly should not be disassembled unless necessary.
To disassemble the servo piston of the amplifier gearbox, it is necessary to remove the O-ring 3 from the servo piston housing (see Fig. 1). Remove from housing 2 (Fig. 4) follower piston 1 complete with collar and O-ring. Remove O-ring 4 and oil seal 5 from piston 1.
Remove the thrust ring 3 from the follower piston housing 2.
To disassemble the front housing of the amplifier and the pneumatic piston, it is necessary to remove from the front housing the O-ring 13 (Fig. 1) of the gearbox diaphragm seat, the pneumatic piston 20 of the amplifier assembly. Remove the collar 23 and guide rings 27 from the pneumatic piston 20.
Fasten the front housing 26 in a vice with the air inlet cover 17 facing up.
Unscrew the cover fixing bolts (4 pcs.), Remove the cover and remove the amplifier reducer valve 14, removing the adjusting and sealing aluminum gaskets 16 from both sides of the valve seat.
Amplifier reducer valve - non-separable design; if necessary, changes in the collection.
Rinse the parts and assemblies of the clutch booster in the solution MS-6, MS-V TU 6-15-978-76, blow them off with compressed air.
The pneumohydraulic booster (PGU) is an integral element of the clutch unit. It reduces the applied pedal effort. Modern pneumatic hydraulic amplifiers have three components:
executive pneumatic cylinder;
indicator of the degree of wear of the lining of the driven disk.
When triggered, the CCGT unit transmits the pressure of the fluid in the master cylinder. It triggers the hydraulic pistons of the CCGT unit and the tracking device. When released, the pressure on the hydraulic piston of the servo system drops, which moves the specified mechanism and the piston of the CCGT unit to the initial position.
Signs of improper operation of the components of the pneumohydraulic booster lie in the features of the clutch, which can:
to be triggered with a delay at the start of movement or when changing gear;
squeeze out with excessive force.
Based on the indicated symptoms of clutch behavior, troubleshooting of the CCGT unit is performed.
If the clutch is "driving", then the problem is with the clutch actuation. Most often, there is no stroke of the lever of the release fork shaft. To solve the problem, check for the presence of working fluid and make sure that there is no air in the hydraulic system. After that, you need to adjust the free play of the lever. Another reason can be the curvature of the driven discs. These discs must be replaced, but you can try to straighten them.
Jamming of the drive is a consequence of swelling of the hydraulic system seals. The problem can be eliminated by completely flushing the hydraulic system followed by changing the fluid.
Lag clutch can be associated with a high viscosity of the working fluid or seizure of the piston of the follower system of the CCGT. In the first case, the liquid is changed to a quality one. In the second, the piston cuff changes.
If it is very difficult to squeeze the clutch and the amplification is completely absent, then the reason clearly lies in the pneumatic hydraulic booster. A possible malfunction is the termination of the supply of compressed air due to the swelling of the CCGT inlet valve. It can also jam the follower piston due to a swollen seal or rubber ring. The third reason is severe wear of the CCGT piston cuff. The solution to the problems is to check the condition and replace the intake valve, the sealing collar or the follower piston ring, the CCGT piston cuff, respectively.
Posts: 17
Location: RK Kazakhstan Kostanay Region
Hello guys. I got a little problem. In short, I wanted to check the fluid level in the clutch reservoir and couldn't find it. Zil 5301 2000, bought recently. Tell?
Posts: 133
Location: Kopeysk
ZIL 5301 Goby ZIL 5301 Goby
open the hood. on the panel under the steering shaft look
Posts: 17
Location: RK Kazakhstan Kostanay Region
hello dear! Tell me, can the pneumatic chambers on the "goby" be repaired or need to be replaced?
Posts: 64
Location: Minsk
ZIL 5301 Goby
Messages: 13570
Location: 66, Yekaterinburg
UAZ Hunter 315195 ZIL 5301 Goby
samostrel, November 6, 2012, 00:19, # 6
Note the stroke of the psu on cold and hot - if the replacement of the clutch disc is the same, but most likely the kit with the basket will have to be changed.
What is the way to determine the replacement of the clutch according to the CCGT
Why are you confusing a person. The clutch housing has a large cover on the bottom, it needs to be removed and then there you can see whether it is necessary to change the clutch.
Messages: 13570
Location: 66, Yekaterinburg
UAZ Hunter 315195 ZIL 5301 Goby
baric452, do as volk73 wrote just start with the clutch master cylinder, here most of all the rubber ring suffers.