The compressor is a universal device that is widely used not only in the automotive sector, but also in production. To save money and avoid purchasing expensive equipment, some craftsmen are trying to create a ZIL compressor on their own.
Device
The compressor is a two-cylinder piston type device. Its operating principle is to pump air through the movement of pistons. The compressor device consists of:
- wire housing with channels;
- oil seal;
- springs;
- seal.
The pistons are made of aluminum and equipped with pins that are secured with retaining rings. Through the intake valves, the air in the engine air filter enters the compressor cylinders. It is compressed by pistons and enters the pneumatic system. Then it passes through the discharge valves, which are located in the cylinder head.
Cooling system
The engine has a closed liquid cooling system. It consists of: radiator, thermostat, pump, temperature sensor, compressor and pipe. It works on the principle of forced circulation of cooling. If the fluid in the system overheats, it is necessary to open the radiator cap. When it is opened, a stream is ejected from the neck hot water. Therefore, this must be done carefully.
Lubrication system
The lubrication system is combined. The lubricant comes from the lubrication unit of the engine system and cools with the help of coolant.
Characteristics
Detailed description of the Zilov compressor. Specifications:
- productivity - 210 l;
- working volume - 214 cm³;
- cylinder size - 60 mm in diameter;
- cylinder - 2 pcs.;
- power consumption - up to 21.1 kW;
- rotation speed - 2000 rpm;
- internal pressure of the pneumatic system - 740 kPa;
- Warranty period - 6 months.
How to make a compressor with your own hands
The device is made by hand using a Zilov compressor. If it is intended to perform small tasks, then alteration of the compressor will be minimal. Its modification is carried out if the device is planned to be used for a long time and with heavy loads. Materials you will need:
- engine;
- receiver;
- pressure gauge;
- safety valve.
“ Good afternoon, fellow engineers!
Help with the compressor. Namely, you need an installation with which you can touch up little things and use a pneumatic impact wrench. It’s the latter that we’ll stick to. Because it already exists. Ingersoll rand impact wrench with air flow 122 l/m and operating pressure 6.5 bar.
In my opinion it will be like this:
1. Receiver 50L (or which one is needed for these tasks?)
2. Compressor ZIL 130 with a forced lubrication system and cooling (fortunately, everything is not difficult with them)
3. The engine is 220V, but what power should I choose?
4. Belt drive - what ratio of pulley diameters is needed?
5. Reducto at the outlet of the receiver
6. Automation - bypass valve, and pressure sensors for automatically turning off and starting the compressor, a check valve of course.
7. Oil separator from a fire extinguisher filled with metal sponges.
If you can tinker with the receiver in terms of volume, then the question is with the choice of engine and pulleys. And in general, can this compressor pump up 14-15 bar (or more).
And one more thing, is it necessary to cool the air? There is an option for a brass tube in front of the engine cooling fan.
Thank you in advance. I'm waiting and hoping for you.1. For a compressor with a capacity of 100-150 l/min, a 50-liter receiver is quite optimal.
2. It is better to use not ZIL 130, but MAZ. At the same speed, the performance of the Mazovsky is 30% higher. It's all about valve design. The Zilovsky valve design is poor.
3. Motor power, maximum pressure and compressor speed are connected by a single functional relationship. The dependence is empirical. I can give personal observations. My single-phase 1.5 kW motor spins the Zilov compressor perfectly at 520-750 rpm at a maximum pressure of 8 atm. At 8 atm it starts up confidently. True, my engine is tricky, with a starting conder and a centrifugal clutch.
4. The pulley ratio is determined by the speed of your electric motor and the number of crankshaft revolutions of the compressor you want to achieve. Decide on the engine and its speed, decide on the crankshaft speed, then ask about the pulley ratio. Let's do the math at our leisure.
5. Gearbox from any Chinese compressor of similar performance. There is a large selection at the bazaars, the price ranges from 500-1000 rubles. Quite reliable.
6. Pressure switch from any Chinese compressor. There is a large selection at the bazaars, the price ranges from 1000-1500 rubles. Quite reliable. A check valve for a Zilov compressor is mandatory, since the original valves do not hold pressure well. It poisons through them quite well. But for a MAZ compressor, a check valve is not needed. The original valves hold up very well. During 12 hours of inactivity on the Mazovsk, the pressure in the 50 liter receiver dropped from 8 to 7 atm.
7. Oil separator if necessary. For 14-15 bar this compressor is not provided. It will be able to pump, but it will take a long time to pump, it will heat up mercilessly and the service life of the oil seal on the crankshaft will be short.
I will be glad if my observations and experience help you.
The compressor is a universal tool that is widely used in various areas of production, including the automotive industry. Ordinary people, in order not to buy expensive models of equipment, decide to assemble such a unit themselves. The ZIL-130 compressor, produced until 2010, is used as a base.
First of all, you should study the characteristics of the ZIL-130 compressor:
- The unit has 2 cylinders, each with a diameter of 6 cm.
- The productivity of the device is 210 liters with a working volume of only 214 cm³.
- The rotation speed is 2 thousand rpm.
- The internal pressure parameters in the pneumatic system are 740 kPa.
- Power consumption does not exceed 21.1 kW.
Compressor device
Such a two-cylinder unit has a piston-type device. The main feature of its operation is the pumping of air, performed by the movement of the pistons. Its design consists of the following elements:
- Stuffing box.
- Springs.
- A wire-type catheter with channels.
- Seal.
Piston compressor
The pistons themselves are made of aluminum, and also have special fingers secured by retaining rings. Through the inlet valves, air is pumped directly into the compressor cylinders. There it is compressed by pistons and then enters the pneumatic system. It then leaves the compressor through special discharge valves.
Lubrication system
This unit uses a combined type lubrication system. So, the lubricant itself is located in a special engine unit. Its subsequent cooling is carried out through the use of coolant.
Unit repair
Separately, it is worth mentioning how such a unit is repaired if any breakdowns occur in it. Breakdowns may be indicated by noise or knocking that occurs during operation of the compressor, or by oil penetrating into the air cylinder being filled:
- The appearance of cracks or chips on the crankcase itself. To eliminate the damage, a complete replacement of the crankcase is required when the damage is located on the walls. Or they are welded in a situation where they are on the mounting flange and also have small dimensions.
- In order to check the tightness of the cylinder itself, it should be placed in a water bath, then under high pressure fill with air. The appearance of bubbles will indicate the presence of damage. To eliminate this problem, the container is bored and then honed to the required size.
- When ball bearings become unusable, they are pressed and then replaced with new ones.
- If the crank pin wear exceeds 0.05 mm, a complete replacement of the crankshaft is required.
- In order to repair the upper head of the connecting rod, it is necessary to press in the repair sleeve, where a hole is made in advance. Its diameter should be 14.019 mm.
The permissible repair size of the piston depends on the number stamped on the bottom of the product. Usually this is +04 or +08.
A special repair kit should be in every workshop where it is planned to use such a product. This will allow you to quickly restore the device to functionality.
Compressor circuit
How to make your own compressor based on ZIL-130
Depending on the volume of tasks that are planned to be performed on the unit, the number of modifications of the ZIL compressor is determined. Its restructuring is required in a situation where long-term operation under increased loads is planned. To do this you will need the following materials:
- Receiver.
- Pressure gauge mounted on the receiver.
- The power plant itself.
- Safety valve.
When you create a compressor yourself, it is important to correctly transfer torque to it. This is what the valve and pressure gauge will be responsible for. The following features should be taken into account during the assembly process:
- Torque. If you plan to connect the power plant to the unit via a pulley and belt, you will need to use a “stronger” engine due to the loss of some power in this way. Because of this, it is recommended to connect through a reducer, although its price is quite high.
- Engine. This element must be selected so that its power parameters meet the needs of the compressor. So, to ensure the required pressure, the rotation speed must be at least 2 thousand rpm. This will allow the unit to operate in cruising mode without significant loads. For short-term use, options delivering a power of 1 kW are sufficient, but for more intense loads, more powerful products should be used.
- Receiver. Created from a medium-sized metal container. This design is equipped with a pressure gauge, as well as a pressure regulator, which is installed at the outlet. At the entrance to the tank, a unit equipped with a gearbox is installed.
- Cooling system. In certain compressor versions, overheating occurs during operation, which requires additional improvement of the standard cooling system.
The compressor itself must be mounted on the frame in a pre-prepared seat. The engine is also mounted there, and other elements are installed separately and connected via hoses.
The ZIL-130 brake system requires a compressor. The operating principle of the modification is based on air injection. This happens in a closed pneumatic system. The device of this series is installed to the right of the motor. To disassemble the ZIL-130 compressor in detail, specifications definitely need to be considered. However, first of all, he recommends familiarizing yourself with the structure of the mechanism.
Compressor ZIL-130: design and operation of the model
The principle of operation of the compressor is based on pumping air. This is achieved through the movement of the pistons. The standard modification includes a wired housing that has channels. There is an oil seal in the central chamber of the system. A spring is installed to operate the supercharger. To from high blood pressure The compressor is not damaged, there is a seal. There is also a rod involved in the device. When it is pulled back, air enters the valve.
Detailed modification parameters
The ZIL-130 compressor has the following: working volume - 214 cubic meters. centimeters, productivity is 210 liters. The power consumption of the presented modification is no more than 2.1 kW. The maximum rotation speed is 2 thousand revolutions per minute. The pressure inside the pneumatic system is maintained at 740 kPa. The ZIL-130 compressor costs (market price) 22 thousand rubles.
Carter modifications
The crankcase on the ZIL-130 air compressor is installed with a rocker arm. Directly at the front of the device there is a special shaft. As a rule, it is lubricated only at the base. The main problem with the crankcase lies in the wear of the struts. To correct this situation, you can disconnect the plug. Next you will need to inspect the drive shaft. To replace the crankcase, the cover is completely removed. If problems arise with the shaft, only the front part of the rocker arm is disconnected.
Discharge mechanism
The pumping mechanism in the device is very compact in size. According to experts, the device can withstand high pressure. Thus, the price for the ZIL-130 compressor is quite justified. The saddle in the device has two outputs. This part does not come into contact with the rocker arm.
The injection mechanism is connected to the crankcase through a tube. The model uses a small diameter shaft. At its base there are two rings and lubricant for the ZIL-130 compressor. A short plug is installed at the end of the shaft. The exhaust valve of the supercharger is used with a protective sleeve. If there are problems with the air supply, the first thing to check is the blower outlet. Next, unscrew the cap and completely clean the valve. The next step, experts recommend checking the spring, since there is a lot of pressure on it.
Crankshaft device
In this case it is connected to the crankcase. The outlet channel is used with a small diameter. The cylinders on the ZIL-130 compressor are installed on the sides. It should also be noted that there are two linings on the bottom side of the modification. The shaft is fixed on the clamp. The fact that the guides of this compressor are installed on the left side deserves additional attention. When the shaft is shorted, experts recommend inspecting the entire supercharger.
The crankcase is also checked, since it usually collects all the debris from recycled oil. To ensure proper operation of the system, the pressure inside the unit is tested. You also need to immediately clean all the channels from the crankcase. This can be done using a regular cleaning rod. The seat is pre-lubricated. If the shaft is deformed, it must be replaced immediately. Prices for ZIL-130 spare parts are quite reasonable. The tip of the part is welded on manually.
Plunger mechanism
The plunger mechanism of this compressor is used with a bearing row. Experts say that the part is able to withstand heavy loads at high speeds. However, it is important to note that the inlet valve needs frequent cleaning. In this case, the channel becomes clogged quite often. To check it, the crankcase is unscrewed. You will also have to remove the cover. An adjusting screw is used to adjust the plunger. When the cover comes out, you can install a large screw. In this case, it is necessary to select the appropriate protective ring. To solve problems with abrasion of the lining, special means are used to seal the block. Some experts recommend periodically cleaning the tubules.
Motorists may also encounter problems with the plunger base. It is a regular plate, which is fixed on a thread. If there is a lot of shaking, the connection breaks down quite quickly. As a result, the plate begins to wobble. To correct this situation, it is recommended to first disconnect the cover. After this, it is important to immediately clean the outlet. The screw unscrews very slowly. In this case, you need to monitor the position of the bearing row.
Device seal
The oil seal on the ZIL-130 compressor is installed with one seal. The camera he uses is small. There are two guides installed at the bottom of the modification. There are stands on the sides of the camera. It should also be noted that there is one support at the top. The crankcase for the ZIL-130 compressor is installed on the right side.
Experts say that the oil seal does not require frequent maintenance. However, it is worth considering that the pads on the support can quickly wear out. In order to inspect them, only the front pillar is removed. Next, it is important to disconnect the block and the oil seal plate. Then the master will be able to directly remove the pads. If small cracks are visible on them, you can try using a sealant. However, if any parts become deformed, experts recommend replacing them immediately.
Replacing the seal
To do it yourself, it is important to carefully inspect the oil seal. As a rule, a lot of soot accumulates on it. It should also be noted that the seals wear out due to overheating of the pad. This happens due to clogged tubules. To correct this situation, it is recommended to unscrew the protective cover of the compressor. After this, the rings are unscrewed. Next, all that remains is to extend the rocker arm. New linings are installed on a well-cleaned surface. Prices for new ZIL-130 spare parts are quite reasonable.
Saddle Inspection
The seat on the ZIL-130 compressor is installed under the discharge mechanism. To inspect it carefully, you need to remove the front connecting rod. After this, the piston itself moves back. The next step is to lift off the protective cover. Its plate is fixed with four screws that can be unscrewed with a key. In this case, the plug is screwed counterclockwise.
Then all that remains is to get to the saddle, which is fixed on the nozzle. There should be a seal at the bottom of the device. In this case, the plate is checked separately. It is also worth inspecting the top of the saddle. Soot often collects on it. You can clean the housing using gasoline. In this case, it is important not to damage the rocker arm.
Plunger repair
If a plunger breaks, repairing the compressor should begin by unscrewing the front crankcase. Next, the protective cap is unscrewed. After this, it is important to remove the two plates that are clamped with rings. If they do not loosen, you can knock them out a little with a hammer. The next step is to inspect the oil seal. As a rule, it accumulates a large number of mud.
If the supercharger is working properly, then everything inside the block should be clean. In this case, the valves are inspected separately. To remove the plunger, it is recommended to use a large wrench. Doing this yourself is problematic due to the fact that you need to constantly hold the piston. In this case, it is more advisable to ask a friend for help.
Air compressor ZIL-130 piston type, two-cylinder. Aluminum pistons with floating piston pins; against axial movement, the pins in the piston bosses are secured with retaining rings.
Rice. Air compressor ZIL-130: 1 - lower crankcase cover; 2 — front crankcase cover; 3 - compressor pulley hub; 4 — crankshaft oil seal; 5 - compressor crankcase; 6 - cylinder block; 7 - connecting rod; 8 - piston with rings; 9 - piston pin with retaining rings; 10 - block head; 11 - discharge valve plug; 12 - discharge valve spring; 13 - discharge valve; 14 - discharge valve seat; 15 - rear crankshaft bearing; 16 - seal spring; 17 - crankcase cover; 18 - seal; 19 - crankshaft; 20 - adjusting bolt; 21 - inlet valve; 22 - intake valve guide; 23 - intake valve stem; 24 - rocker spring; 25 - rocker arm, 26 - plunger; 27 - sealing rings; 28 — intake valve stem socket; 29 - intake valve spring
The block and head are cooled by liquid supplied from the engine cooling system. The liquid in the compressor cooling system is supplied from the water jacket of the engine intake pipe to the cylinder block, then to the compressor head and drains from the head into the suction cavity of the water pump.
Adjusting the ZIL-130 compressor
At each maintenance it is necessary to check:
- tightening the compressor mounting nuts on the engine head
- pulley fastening
- drive belt tension
- tightening the nuts of the studs securing the head and other fasteners
The nuts of the studs securing the head should be tightened evenly in two steps. The final tightening torque should be within 1.2-1.7 kgf*m.
The compressor drive belt must be tensioned so that when a force of 4 kgf is applied, the deflection of the belt branch located between the compressor and fan pulleys is 5-8 mm. Belt tension should be checked daily. The tension of the compressor drive belt is regulated by moving the compressor, which requires loosening the nuts securing the bottom cover to the bracket and using the adjusting bolt 20 to ensure the required tension. After this, tighten the compressor mount and lock the adjusting bolt with a locknut.
The pressure regulator automatically maintains the required compressed air pressure in the system by admitting air into or out of the compressor unloader.
The pressure regulator is adjusted in the following sequence:
- By rotating the cap, it is ensured that the compressor starts working at a pressure of 6.0-6.4 kgf/cm2. When screwing the cap, the pressure increases, when unscrewing it decreases. The cap is secured with a locknut.
- By changing the number of gaskets, a pressure of 7.3-7.7 kgf/cm2 is obtained, at which the compressor is turned off. As the number of gaskets increases, the pressure decreases; with a decrease, the pressure increases.
