Changchai L26 User manual

L26/L28/L30/L32
DIESEL ENGINE
-changchai OPERATION MANUAL

CONTENTS
~reface(To the Customers)
Overall and Mounting Dimensions of L26/L28/L30/L32 Diesel Engines
Overall and Mounting Dimensions of L26M/L28M/L30MIL32M Diesel Engines
Schematic Drawing of Lubrication System
Section IPrincipal Technical Specifications and
Data····················· (1)
Section II Mounting of the Engine and Coupling of the Driven Machine with
the Engine ··········································································· (3)
Section mOperation of the
Engine············································· (4)
Section WAdjustment and Maintenance of the Engine············ (7)
Section VElectrical Starting System·········································· (12)
Section VI Defects and Elimination············································· (14)

PREFACE
(To the Customers)
Many thanks for your purchasing our CHANGCHAI brand L261L281L301L32 diesel engines.lt is
recommended that the operator,before operating the engine,reads the manual carefully.
CHANGCHAI brand L261L281L30/L32 diesel is of single cylinder,horizontal,four -stroke,water
coolded,direct injection engine.The L261L28/L30/L32 diesel engines have the advantage of more
powerful output,higher torque reserve,lower fueVwater consumption,easy starting,high safety coefficient,
reliable operation,convenient maintenance and wide applications.
L261L281L30/L32 diesel engines have the same dimensions,power take-off and operation method as
the predecessor ZS1125.They are suitable
for powering small sized 4-wheel tractors,boats,engineering
machinery,they can also be used as aprime mover
for transportation vehicles,small electric generators
and agricultural processing machines.
For noraml,reliable and safe operation of the engine,it is hope that the operator,when operating the
engine,pays close attention
to the following:
l.1t is forbidden
to touch high temperature parts such as water hopper and silencer,and moving parts
such as flywheel and starting shaft
to prevent being scalded and injured.Keep the fuel tank away from
fire and never direct the exhaust towards inflammables such as straws,haystacks and cotton to' avoid
dangers.
2.Children,the aged
who acts slowly and the person who has abnormal behaviors are not allowed to
enter the working site.
3.When coupled with driven machines,the engine should develop its rated output at rated speed as
specified on the name plate,avoid running the engine with overload and at overspeed or with underload
and at
low speed for along time.lt is forbidden to run the engine in the absence of watchers.
4.A fuel and alubricating oil of specified grade is
to be used,and before being used,they should be
completely precipitated and thoroughly filtered.Any utensils used herein should be kept clean.And the
used lubricating oil should be periodically changed.The element of fuel filter and the screen of sump
strainer should be periodically cleaned.
5.Fill the air filter with oil up
to the oil level line.Regular clean,maintenance and change of oil
should be done.Especially when the engine is used
for powering tricycles and small sized 4-wheel
tractors,operating in very windy and dusty condition,clean,maintenance should
be done every day.
6.Clean soft water is used for cooling water.The engine is
to operate under boiling condition of the
cooling water in the hopper.The quantity of water should always be kept in such a
way that the red ball
of the float must not
go down below the mouth of the funnel of the hopper.
7.Regularly check the mounting connection and fastening bolts of the engine parts for looseness.lf
any looseness is found,tighten it at once.

8.The fuel,controller fitted on the gear casing has been adjusted and sealed before engine shipment.
Do not take off or adjust it at random.
9.The users must drain out completely the cooling water of the engine in winter.While the cooling
water can not be
to drain out completely,it is necessary to screw off the water-drain cock or cylinder
head and must clean all the dirt.
It is hope that the operator make acorrect operation and maintenance of the engine,do not allow the
engine
to run under abnormal condition.Then high quality Changchai brand L26/L28/L30/L32 eilgines
will certainly build up your family fortunes.
Since improvements on products and broadening of applications are made from time
to time,your
engine may be slightly different from instructions and statements contained within this manual.They
won",! be altered until the new revised edition is published.The users are requested to pay attention to
this.

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Overall and mounting dimensions of L261L281L301L32diesel engines
Overall and mounting dimensions of L26MIL28MIL30MIL32M diesel engines

Schematic drawing of lubrication system
I.Pipe connection seat
5.Pipe connection bolt
2.Pipe connection 3.Connecting pipe 4.Sump strainer
6.Washer 7.0il pump 8.0il pressure indicating float

Section IPrincipal Technical Specifications
A.Technical Specifications
Items Specifications
Engine Model L26
L2S ju6M
L28M
L30 I.J2
L30M I.32M
Type Single cylinder.four stroke,horizontal type
Combustion Chamber Direct injection
Cylinder bore(mm) 120 125 120 125 125 130 125 130
Piston stroke(mm) 120
Piston displacement
(L )1.357 1.473 1.357 1.473 1.534 1.659 1.534 1.659
Rated. output/Rated speed
18.51 201 18.51 201 211 23/ 21/ 23/
(kW/r/min)
2200 2200 2200 2200 2200 2200 2200 2200
Specific fuel consumption 244.8
(g/kW-h)
Specific lube oil consumption 2.04
(g/kW·h)
Cooling method Water cooled,evaporative
Starting inethod hand cranking Electrical hand cranking Electrical
Fuel injection pressure(MPa) 19.13
Net weight(kg) 205 208 217 220 210 212 222 224
Overall dimensions
(LxWxH) 916x475x709978x475x709916x475x709978x475x709
(mm)
B.Principal Technical
Data
Intake valve(mm) 0.35±O.05
Valve clearance(cold) Exhaust valve(mm)
O.45±0.O5
Fuel injection ~iming
20
o-23°before T.D.C.
Cylinder head nut(N
·m)
385-415
Connecting rod bolts(Nem) 100-120
Tightening torque of
main bolts and nuts Flywheel nut
320-370
Balancing block
100-120
bolts of crankshaft
- 1 -

C.Models and Specifications of Main Fitting Components(L26JL28)
Items Models/Specifications
Fuel injector PF68S125
Nozzle couple ZCK154S530A
Fuel injection pump B139-1
Lube oil pump Rotor type
Fuel filter C0506C
Models and Specifications of Main Fitting Components(L301L32)
Items Models/Specifications
Fuel injector PF68S125
Nozzle couple ZCK154S530A
Fuel injection pump BFIAWI05Z01
Lube oil pump Rotor type
Fuel filter C0506C
- 2 -

Section II Mounting of the Engine and
Coupling of Driven Machine with the Engine
A.Mounting of the Engine
The engine should be bolted down to arigid base with the same mounting dimemsions as
the diesel engines of its kind(see the drawing of overall and mounting dimensions of the enigne).
The axial dimensions of the pulley of the driven machine should coincide with that of the engine
to avoid torsion of the V-belts.
The engine and driven machine should be in
good coupling.Protection measures of the
flywheel and belt pulley should be taken
to avoid danger.
B.Selection of the Size of the Pulleys
When the engine IS used to drive working machines,the user should make acorrect selection
of the size of pulleys
to ensure normal operation of the engine and driven machines.The size of
pulleys
may be calculated according the following formulas:
Where Dhis the diameter of the pulley on the engine shaft(use pitch diameter in case V-belt is
used) ;
D2 ,the diameter of the pulley on the shaft of the driven machine(use pitch diameter in
case V
-belt is used);
nl ,the rotative speed of the engine;
n2, the rotative speed of the driven machine.
One piece of
V-belt pulley,148mm in outer diameter,is attached to the engine on its delivery
from the maker's works.Pulleys of special specifications may be provided through negotiation when
customer place an order.(Don't increase the diameter
to get more efficiency and higher speed.Our
company will not .bear three guarantees responsibility for this)
- 3 -

Section ill Operation of the Engine
A.Preparation before Operation
1.Lubricating oil
1.1 Lubricating oil for the engine should conforln
to the standard of GB11122-1997.Use
lubricating oil of CC20W/40 grade in summer,CC10W/30 grade
in winter.
1.2 Lubricating oil should be stored in aclean and tight container to prevent dirt from
getting in.Before adding oil,draw out the dipstick and pour clean oil into the crankcase.The
quantity of oil added is about 4.5 litre so that the oil level in the crankcase will lie between the
two marked lines on the dipstick.Caution:The oil level must not go over the upper line,nor fall
down below the lower one.
2.Diesel Fuel
2.1 Fuel for the engine should conform
to the standard of GB252-2000.Use light diesel fuel
NO.O in summer,No.-lO or No.-20 in winter.
2.2 Open the fuel tank,pour into it clean diesel fuel already thoroughly precipitated and
filtered.Any utensils used herein should
be kept clean.
2.3 Open the fuel cock.Then fuel will flow through the fuel filter to the injection pump.
2.4 Loosen the vent screw on the fuel injection
pUUlp or loosen the fuel pipe connections,in
order that air,if any,in the fuel
pipe line rnay get out.When it is noted that fuel without air
hubbIes flows out,re-tighten the vent screw
or connections.
3.Cooling water
Clean soft water such as faIn water,snow water or river water is used.Pour it into the hopper
until the red ball of the float rises upto its top position.N·ever
use foul water or hard water such
as well water.In case hard water has
to be used under particular condition,a soften treatment
should be made by asimple
way of boiling and precipitating before use.Otherwise,the blockage of
water passages or erosion of hopper Inay occur.The cooling water in the hopper should be
changed regularly and
be free from foreign Inatter and dirt.
B.Starting the Engine
Acareful check should be made after preparations mentioned above have been done.Then
start the engine according to the following procedure.
1.Set the speed-control knob
at "START' position indicated on the panel.
2.Insert the starting crank into the starting shaft hole.Push down the decompression lever and
crank the engine,until anormal fuel injecting sound is noted
..
3.Speed up the cranking of the engine to tnake the flywheel gain enough inertia,then
suddenly release the decompression lever,but continue
to crank the engine with efforts.Then the
engine will start running itself.
- 4 -

4.0nce the engine starts up running,the starting crank,because of the action of the spiral
jaws on its clutching end,will
jerk out of itself,and therefore the operator must keep on holding it
firmly and gently take it off from the starting shaft hole to prevent any incident.
C.Running of the engine
Caution:While running the engine,take precautions against winding,scalding· and fire.
It is hope that the operator pays attention to the safety marks nearby the filler of fuel tank,
water tank
cap of the radiator,flywheel,gear casing starting shaft and silencer.
I.After starting the engine,check the red float in the oil indicator and see if it rises up.In
case it fails to rise
up or suddenly drops down,stop the engine and fill it with sufficient quantity
of oil or remedy the trouble.
2.Allow the engine to run idle at low speed for 3-5 minutes after its being started.When the
temperature of cooling water becomes relatively high,gradually increase the engine speed and
lo~d.
Never run the engine at high speed and with full load immediately after starting.
3.The water in the hopper keeps boiling during the operation of the engine.Sufficient quantity
of fresh water must
be fed in at once when the red ball of the float goes down to the mouths of
the funnel of the hopper.
4.The engine is not allowed to run under black smoke exhausting conditions.During the
operation of the engine,the operator should pay close attention to the color of the exhaust.!n case
black smoke
in the exhaust is found,if everything else is normal,the load on the engine should" be
reduced or remedy the trouble.
5.If any abnormal noise is noted during the operation of the engine,stop it immediately for
check.
6.A new engine IS not allowed to operate with full load In its first 50 hours of operation.
After aperiod of 40-50 hours,it is necessary to check and retighte~ all the loosened bolts and
nuts.
De.Stopping the Engine
I.Gradually unload the engine and then slow down the speed of the engine and let it run
idle for several munites.Shift the speed-control lever knob to "STOP" position,the engine will then
stop running.
2.Under particular conditions vihere emergency stop is necessary,it is advisable to loosen any
of the connections of the high pressure fuel pipe or use clothes or towels at hand to block the
inlet of the air filter. The engine can also be stopped by putting the decompression device into
action.
E.Precautions After Stopping the Engine
I.Close the fuel tank cock.
- 5 -

2.If the engine is to be put out of service for along period of time,it is necessary to drain
out the cooling water by opening the draining cock
on the cylinder head.Especially in winter,the
cooling water must be drained out immediately after the engine has been stopped in order
to
prevent subsequent cracking of the cylinder blcok and other parts as well because .of freezing.
3.Turn the flywheel until fail
to turn it.Then push down the decompression lever and
continue
to turn the flywheel until the marked line on the flywheel matches with the marked line
on the hopper, so that both the intake and exhaust valves are set under closed condition and the
piston is set at the top dead centre position in the compression stroke in order
to prevent any
dust
from getting into the cylinder.
4.Periodically dismantle the draining cock,clean the water passages and remove the scale.
5.Check the connection between the engine and its support often.Check and retighten all the
loosened bolts and nuts.
- 6 -

Section NAdjustment and Maintenance of the Engine
A.Adjustment of Valve Clearance
I.Remove the cylinder head cover.
2.Turn the flywheel until the mark Ton its periphery coincides with the marked line on the
hopper in order
to set the piston at its top dead centre position in the compression stroke.
3.Loosen the locking nut and turn the adjusting screw on the rocker arm with ascrew driver
to set the valve clearance to the specified value (the intake valve clearance is O.35mm,and the
exhaust O.45mm)by means of afeeler gauge inserted between the valve stem and the rocker arm.
4.In the course of adjustment,screw in the adjusting screw
to such an extent that the' push
rod is just free to turn but not
too 100se.When this is done,tighten the locking nuts in order to
prevent any loosening afterwards.
5.Draw out the feeler gauge,and re-check the valve clearance.
B.Adjustment of Injection Timing
I.Disconnect the high pressure fuel pipe from the injector.
2.Loosen the nut which connects the high pressure fuel pipe
to the injection pump,turn the
pipe around
so that the open end of the pipe is upwards,and re-tighten the nut.Then prime the
injection pump until the high pressure fuel pipe is full of fuel.
3.Tum the flywheel slowly until the fuel just begins
to flow out of the end of the pipe.Stop
turning and check whether the injection timing mark line on the periphery of the flywheel
coincides with the mark line on the hopper.In case the injection timing is
too advanced or too
lagging behind,adjustment is then necessary and should be made according to the following
procedure.
(I )Shut off the fuel filter cock.
(2)Set the speed-control lever knob at the middle position.
(3)Disconnect the high pressure fuel pipe
from the fuel pump.
(4)Screw off the pump fixing bolts and take off the pump.
(5)Increase or decrease the number of shims
for adjustment.Increase the number of shims if
injection timing is advanced.Decrease the
nu~er of shims if lagging.
(6)Mount back the injection pump and tighten the fixing bolts.While doing so,it is necessary
to pay special attention to that the ball of the plunger adjusting arm must be engaged with the
slot in the speed-governing fork inside the gear casing.This should be checked again through the
inspection hole after the pump has been mounted back in order
to prevent the engine from"
mnning away"resulting from possible mis-mounting.
After adjustment,it is advisable
to check again according to the above -mentioned item 3.
Readjustment is necessary if something is found incorrect.Caution:The adjustment of injection
- 7 -

timing of each engine has already been made carefully by the engine manufacturer.Therefore it is
not recommended that the engine operator increases or decreases the number of shims at option,
which would aftect the normal operation of the engine.
C.Adjustment of Decompression Device
The good function of, the decompression device may be tested by hand feeling in the
floolwing way:Tum the decompression lever clockwise with your left hand,and at the same time,
crank the engine with your right hand by means of the starting handle.If your left hand feels
heavy while your right hand feels light,then the decompression device works correctly.However,
attention should be paid to that the decompression shaft must not touch the rocker arm while
cranking the engine,after the decompression lever has been released back.
If the contrary is the case,adjustment must be made as follows:
I.Remove the deecompression cover on the cylinder head cover.
2.0ne hand hold the decompression lever,the other hand loosen the locking nut,tum the
adjusting screw by adriver.After the adjustment,tighten the locking nut again.
3.Mount back the decompression cover.
D.Maintenance of the Engine
The maintenance of the engine should be conducted as the following items and requirements.
- 8 -'

Item
1.Cooling water
2.Lubricating
oil
3.Lubricating
oil stariner
4.Air filter
5.Fuel filter
element
6.Main bolts
and nuts
Maintenance of the Engine
Maintenance
As soon as the red ball of the float in the hopper goes down
near the mouth of the funnel,replenish water.
As soon as the oil level in the sump drops down near the
lower marked line on the dipstick,replenish oil.
After the first 50 hours of operation of anew engine,it is
necessary
to clean the crankcase and the oil sump,and
renew the oil.
Hereafter,. the oil must be changed once every 100 hours of
operation.
After the first 50 hours of operation of anew engine,it is
necessary
to dismantle the strainer and clean it.
Hereafter,the strainer must be cleaned once every 100
hours of operation.
Ordinarily,the filter is
to be cl~aned once every 100 hours
of engine operation.
But when the engine is used
to power awalking tractor,the
cleaning of the filter is
to be done every 50 hours of
operation.
In case the engine is operating in adusty atmosphere,it is
necessary
to clean the filter every shift of work.
Clean the paper element of the filter with clean fuel or
kerosene and
blow it from inside out,replace it if damaged.
Retighten main bolts and nuts.with required torques after
first
40-50 hours operation of a new engine.
Retighten them every 300 hours of operation after this.
- 9 -
Period
as required
-Everyday
First 50 hours
100 hours
First
50 hours
100 hours
100 hours
50 hours
Every shift
100 hours
First
40-50
hours
300 hours

filling screen
7.Fuel
Item
tank
and
Maintenance
Remove the
screen from the inlet of the fuel tank and clean I
it in fresh fuel.
Clean the inside of the fuel tank with clean fuel.
-'r---
Period
50 hours
500 hours
8.Lapping
of valve
9.Valve
clearance
10.Cylinder head,
cylinder
liner
and piston-
connecting rod
assembly
II.Oil ducts in
the crankshaft
12.Cooling water
passages
Smear the valve seat with alittle bit of lapping paste and
lap it together with the valves carefully (Caution: do not let
the lapping paste get into the valve guides).
After lapping,wash the valves and the valve seats with fresh
fuel
and wipe them dry.Checking the valve for tightness
may
be done by pouring into the intake and exhaust ports a
slnall quantity of fuel and ubserve whether it leaks out
around the valve seats.
Adjust according to the recommended procedure.
Remove carbon deposit
if any,and clean them ~?ith fresh
fuel.!t may not
be necessary to dismantle them for cleaning
if the engine operates normally.
Clean the center hole of the crankpin and oil passages in
the crankshaft ,vith fresh fuel.
Pour into the water passages asolution of hydrochloric acid
(HCI) of 25% concentration,keep it for about 10 minutes
and then blow -wash with fresh ,vater. Repeat it if not
thoroughly cleaned.
Note: the hopper must be removed fronl the engine before
cleaning.
-10 -
500 hours
100 hours
1000 hours
200 hours
500 hours

Item
13.Fuel injt?ctor
Maintenance
ICheek fuel injection pressure and sprayablility of the
injector.Normally the spray is in 4concentrated
jets pattern
and no fuel dribbing or non -atmozied jet IS found.!f
necessary,clean the nozzle couple
and remove carbon
deposits inside the injection orifices with a
00.30mm
needle.!n case fuel dribbling IS found and no clear"
chattering"is heard when spraying it is necessary to
lap the
fitting surfaces of nozzle couple with alittle bit of lapping
paste.After washing and reassembly.Readjust fuel injection
pressure again.
-:- 11 -
Period
as required

Section VElectrical Starting System
A.Wiring diagram of Electrical Starting System
KZT-12D
Flywheel generator
B.Main Elements of Electrical Starting System
The maIn elements of electrical starting system is composed of starting motor,flywheel
generator,voltage regulator,starting switch and battery.
I.Starting motor
Model QD139G motor is used,with arated power of 3kW and avoltage of 12V.lt is of
shorttime rating design with abattery as its power supply.The motor is fitted with asolenoid
operated switch and an one way clutch.When it is connected to power supply,since the action of
the solenoid-operated switch,its pinion will be pushed out and engage with the ring gear on the
flywheel,thus the engine will start mnning up.The clearance between the end surface of the motor
pinion and the end surface of flywheel is 3.5-5mm,which can be adjusted with insulating shims.
2.F1ywheel generator
Flywheel type charging generator is used,with arated capacity of 150-300W at user~s option,
and avoltage of 12V.It is used together with regulator.It is also used for charging the battery for
electrical starting operation and lighting power source.!f generator be used or not may customer
option.
3.Voltage regulator
Model KZT -12D regulator is used.It rectifies AC produced by the generator,regulates its
voltage to 14V and charges the battery.And it has the function of .automatic limitation of voltage.
4.High capacity battery for starting use,self-provided by the users,with arated capacity of
noless than 150Ah and arated voltage of 12V.
5.Circuit key switch
-12 -

Model JK424 ignition key switch is used,with four positions:
5.1 Initial position
"0" (Circuit is disconnected)
5.2 Position" I
"(Tum the key clockwise)
5.3 Position"
n" (Continue to turn the key clockwise)The key can tum back to position" I"
automatically.
5.4 Position"m"(Tum the key counterclockwise
from position"O")
C.Operation Procedure of Electrical Starting
1.Preparation before starting
1.1 Check all the wiring connections for tightness.
1.2 Check
to see if there is adistance of 3.5-5mm between the two end surfaces of the
pinion of the starting motor and the ring gear.
1.3 Check
to see if the key switch is at position"O".
2.Starting
Insert the key into the JK424 switch and tum it
to position" I",then the battery will be put
in the main circuit of the starting motor.After that,tum the key
to the position" n"then the pinion
of the starting motor will come out and engage with the ring gear
to rotate the flywheel.In most
cases the engine will start up running and the charge-indicating lamp will light up.After starting,
turn the key back
to the position" I"immediately,and the pinion of the starting motor will draw
back of itself and disengage with the ring gear.Once the engine starts running normally,turn the
key
to the position" m" to put the starting motor and the battery in the circuit,then the current
pointer will shift in"
+" direction,which indicates that the charging of the battery is under way
normally.
3.Precautions
3.1 Each starting operation must not last over 5seconds,and the maximum duration must not
over
15 seconds.The interval between the two consecutive starting operation shall be at least 2
minutes.Otherwise the starting motor will be burnt out and damaged.
3.2 Never turn the key
to the position" II "during the running of the engine to prevent the
pinion of the starting motor and the ring gear
from being damaged due to their collision.
3.3 Tum the key back
to position" 0" and take it out after stopping the engine.H the engine
is
to be put out of service for along time,it is advisable. to disconnect the wires from the battery
to prevent the generator from being burnt out.
3.4 In case of failing
to starting the engine on several consecutive times,it is recommended
to refer to the related operation manual and check the electrical system of the engine or consult
the professional for maintenance.
3.5 Wiring connections of starting motor.
All the conducting wires must as short as possible.Sectional area of the copper wlnng with
the battery must no-less than
25 mm
2,and sectional area of the wire with the starting switch must
no-less than 4mm2also.
-13 -

Section VI Defects and Elimination
A.Engine Fails to Start
Cause
l.In cold weather,lube oil
becomes too viscous,difficult
to
crank the engine
2.Faults in fuel system
2.1 Unsteady fuel
flow
2.2 Freezen fuel
2.3 Air in fuel pipe line
2.4 Fuel injection timing
incorrect
2.5 Insufficient fuel injection
pressure,ne~dle valve seized,
injection orifices choked with
carbon deposits
2.6 Pumping element (Plunger
and barrel of the injection pump
worn out)
3.Insufficient compression in the
cylinder
Remedy
---
Fill the hopper with hot water.Use lube oil of specified grade or
preheat lube oil before pouring it into the oil sump,but
do not
heat the oil sump with external fire.If necessary,disconnect the
engine from the driven machine by pulling off the belt,then start
the engine.Stop it after the engine has been warmed up,reput the
belt on and start the engine again.
Check-the fuel tank and the element of the fuel filter whether
there is any water or dirt.Clean the element in clean fuel if it is
choked with dirt,or clean the fuel tank and fill it with clean fuel
of recommended grade if any water is found
in the tank.
Use fuel of specified grade and heat it.
Release air and tighten all of fuel pipe connections.
Adjust according
to recommended procedure.
Clean,lap or renew the_injector nozzle,adjust injection pressure to
specified value.
Renew pUlnping element(Plunger and barrel)
-14 -