Mitsubishi Heavy Industries L2E Manual

Printed in Japan Pub. No.
Pub. No.
OPERATION&
OPERATION&MAINTENANCEMANUAL
MAINTENANCEMANUAL
Pub. No.
The operator and supervisor are requested to read this Oper-
ation and Maintenance Manual carefully before operating the
engine or conducting inspection and maintenance.
Never operate the engine or conduct maintenance work with-
out completely understanding this manual.
November 2007
November 2007
99610-15130
99610-15130
99610-15130

i
Pub. No. 99610-15130
FOREWORD
This operation and maintenance manual contains detailed operation, inspection and maintenance
information for Mitsubishi engines.
Please read this manual thoroughly before proceeding with operation, inspection, and maintenance
work for correct use and servicing.
Failure to follow directions in this manual may result in serious accidents.

FOREWORD
ii
Limited warranty
The manufacturer will repair or replace parts returned to the manufacturer when the manufacturer judges after
inspection that the parts are defective in material and/or workmanship.
The manufacturer's warranty is limited to the repair work or replacement of parts for the defective parts only.
The warranty coverage is effective for the original purchaser only. Those to whom ownership is later transferred are
not provided with the warranty.
• The manufacturer makes no warranties, either expressed or implied, except as provided in this
manual, including, but not limited to, warranties as to marketability, merchantability, fitness for a
particular purpose or use, or against infringement of any patent.
• The manufacturer will not be liable for any damages or consequential damages, including, but
not limited to, damages or other costs resulting from any abuse, misuse, misapplication of the
engine and devices supplied by the manufacturer.
• The manufacturer will not be liable for any damages or personal injuries resulting from any
modification, without the manufacturer's written permission, of the engine and devices supplied
by the manufacturer.
• The manufacturer will not be liable for any damages or production losses caused by the use of
fuel, engine oil and/or long life coolant (LLC) that are not recommended by the manufacturer.
• The owner of the engine is responsible for the performance of the required maintenance listed
in this operation manual. The manufacturer may deny the warranty coverage if the engine or
part has failed due to inadequate or improper maintenance.

FOREWORD
iii
Emission warranty
The following warranty applies to the engines that are approved of the emission regulation of the U.S Environmental
Protection Agency.
Warranty coverage
Mitsubishi Heavy Industries warrants to the first owner and each subsequent purchaser of a new L series diesel
engine that the emission control system of your engine:
• is designed, built and equipped so as to conform at the time of sales with all applicable regulation of the U.S Envi-
ronmental Protection Agency. If the vehicle in which the engine is installed is registered in the sate of California, a
separate California emission regulation also applies.
• is free from the defects in material and workmanship which will cause the engine to fail to meet these regulations
within the warranty period.
Warranty period
The emission warranty period is shown below.
However, if your engine warranty period is longer than the emission warranty period, the emission warranty period
extends to same as the engine warranty period.
Below warranty period shall begin on the date the engine is delivered to the first owner.
Warranted parts
Mitsubishi Heavy Industries warrants the parts which will increase the emission of pollutants when they become
defective.
The followings are examples.
• Inlet/Exhaust manifold
• Crankcase ventilation system
• Fuel system
• Fuel injection nozzle
Limited warranty
Refer to "Limited warranty"
If your engine is certified as Anditsmaximum
power is And its rated speed is Then its warranty period is
Variable speed or constant speed kW < 19 Any speed 1,500 hours or two years, whichever
comes first.
Constant speed 19 ≤kW < 37 3,000 min-1 or higher 1,500 hours or two years, whichever
comes first.
Constant speed 19 ≤kW < 37 Less than 3,000 min-1 3,000 hours or five years, whichever
comes first.
Variable speed 19 ≤kW < 37 Any speed 3,000 hours or five years, whichever
comes first.
Variable speed or constant speed kW ≥37 Any speed 3,000 hours or five years, whichever
comes first.

FOREWORD
iv
Important information
• To avoid potential hazard, accident prevention activ-
ities must be planned methodically and conducted
continually by considering all aspects of engine
operation, maintenance and inspection.
All related personnel, including managers and
supervisors, should actively participate, recognize
their roles and organize themselves and their work
to ensure a safe environment.
• The foremost safety objective is to prevent acci-
dents that may result in injury or death, or equip-
ment damage.
• Always observe laws or regulations of the local or
federal/national government.
• The manufacturer cannot foresee all potential dan-
gers of the engine, potential danger resulting from
human error and other causes, or danger caused by
a specific environment in which the engine is used.
Since there are many actions that cannot be per-
formed or must not be performed, it is impossible to
indicate every caution in this manual or on warning
labels. As such, it is extremely important to follow
directions in this manual and also to take general
safety measures when operating, maintaining and
inspecting the engine.
• This manual has been prepared for people whose
native language is English. When the engine is used
by individuals whose native language is not English,
the customer is requested to provide thorough
safety guidance to the operators. Also add safety,
caution and operating signs that describe the origi-
nal warning label statements in the native language
of the operators.
• The engine must be operated, maintained and
inspected only by qualified persons who have thor-
ough knowledge of engines and their dangers and
who also have received risk avoidance training.
• To prevent an accident, do not attempt to carry out
any operation other than those described in this
manual, and do not use the engine for any unap-
proved purpose.
• When the ownership of the engine is transferred, be
sure to provide this manual with the engine to the
new owner. Also inform the manufacturer of the
name and address of the new owner of the engine.
• This manual is copyrighted and all rights are
reserved. No part of this manual, including illustra-
tions and technical references, may be reproduced,
photocopied, translated, or reproduced in any elec-
tronic medium or machine readable form without
prior written consent from the manufacturer.
• The contents in this manual are subject to change at
any time without notice, for improvement of the
engine.
• Pictures or illustrations of the product in this manual
may differ from those of product you have.
• Please note that, depending on specifications, items
described in this manual may differ in shape, or may
not be installed on the product you have.
• Please contact your Mitsubishi dealer if you need
more information or if you have any questions.
• If you lose or damage this manual, obtain a new
copy at your Mitsubishi dealer as soon as possible.
• Mitsubishi Heavy Industries recommends the
engine owner to install an hourmeter on the engine
due to monitor correct service intervals and to per-
form the maintenance at the proper timing.

FOREWORD
v
Warning Indication
The following two means are used to call the attention of the operators and maintenance personnel to potential dan-
gers of the engine.
• Warning statements in the manual
• Warning labels affixed on the engine
Warning statements
The warning statements in this manual describe potential danger in operating, inspecting or maintaining the engine,
using the following five classifications to indicate the degree of potential hazard. Failure to follow these directions
could lead to serious accidents which could result in personal injury, or death in the worst case.
Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
Indicates a potentially hazardous situation which, if not avoided, can result in property
damage.
Note: Indicates important information or information which is useful for engine operation.
'$1*(5
:$51,1*
&$87,21
&$87,21

FOREWORD
vi
Units of measurement
Measurements are based on the International System of Units (SI), and they are converted to the metric system
units in this manual using the following conversion rates.
• Pressure: 1 MPa = 10.197 kgf/cm2
• Torque: 1 N⋅m = 0.10197 kgf⋅m
• Force: 1 N = 0.10197 kgf
• Horsepower: 1 kW = 1.341 HP = 1.3596 PS
• Meter of mercury: 1 kPa = 0.75 cmHg
• Meter of water: 1 kPa = 10.197 cmH2O (cmAq)
• Engine speed: 1 min-1 = 1 rpm
Abbreviations, standards and others
• API = American Petroleum Institute
• ASTM = American Society for Testing and Materials
• JIS = Japanese Industrial Standards
• LLC = Long Life Coolant
• MIL = Military Specifications and Standards (U.S.A.)
• MSDS = Material Safety Data Sheet
• SAE = Society of Automotive Engineers (U.S.A.)

CONTENTS-1
CONTENTS
Chapter 1
BASIC SAFETY PRECAUTIONS
Fire and explosion...............................1-1
Keep flames away............................................ 1-1
Keep engine surrounding area tidy and clean..1-1
Care for fuel, oil and exhaust gas leakage....... 1-1
Use explosion-proof lighting apparatus............ 1-1
Prevent electrical wires from short-circuiting.... 1-1
Keep fire extinguishers and a first-aid kit handy1-1
Stay clear of all rotating
and moving parts.................................1-2
Install protective covers around rotating parts . 1-2
Check the work area for safety ........................ 1-2
Stay clear of moving parts during
engine running ................................................. 1-2
Lockout and Tagout ......................................... 1-2
Keep engine stopped during servicing.............1-2
Always restore engine turning tools after use.. 1-2
Changing the engine speed setting is prohibited1-2
Be careful of exhaust fume poisoning .1-3
Operate the engine in a well-ventilated area....1-3
Protect ears from noises......................1-3
Wear ear plugs................................................. 1-3
Be careful of falling down ....................1-3
Lift engine carefully.......................................... 1-3
Be careful of burns ..............................1-4
Do not touch engine during
or immediately after operation.......................... 1-4
Do not open the radiator filler cap
when the engine is hot..................................... 1-4
Add coolant only after the coolant
temperature dropped........................................ 1-4
Be careful of handling fuel,
engine oil and LLC...............................1-4
Use only specified fuel,
engine oil and long-life coolant (LLC)............... 1-4
Handle LLC (long life coolant) carefully ........... 1-4
Proper disposal of waste oil and coolant (LLC)1-4
Service battery.....................................1-5
Handle the battery correctly............................. 1-5
When abnormality occurs....................1-5
Do not add coolant immediately
after a sudden stop due to overheating............1-5
Avoid immediate restart after abnormal stop....1-5
Avoid continuous engine operation
at low oil pressure ............................................1-5
If the fan belt breaks,
stop the engine immediately ............................1-5
Other cautions.....................................1-6
Never modify engine ........................................1-6
Never break the seals ......................................1-6
Perform all specified pre-operation
inspections and periodic inspections................1-6
Break-in the engine..........................................1-6
Warm up the engine before use.......................1-6
Never operate the engine
in an overloaded condition ...............................1-6
Conduct cooling operation
before stopping the engine...............................1-6
Protection of the engine against water entry....1-6
Properly maintain the air cleaner
and pre-cleaner................................................1-7
Observe safety rules at work site.....................1-7
Work clothing and protective gear....................1-7
Use of tools optimum for each work.................1-7
Do not operate the starter for a prolonged time1-7
Do not turn off the battery switch
during operation ............................................... 1-7
Cautionary instructions
for transporting the engine ...............................1-7
Do not touch high-pressure injection fuel.........1-7
Chapter 2
NAMESOF PARTS
Engine external diagrams...................2-1
L2E Left view....................................................2-1
L2E Right view .................................................2-1
L3C,L3E Left view............................................2-2
L3C,L3E Right view..........................................2-2
Equipment and instrument..................2-3
Starter switch ...................................................2-3
Preheat indicator..............................................2-3

CONTENTS
CONTENTS-2
Automatic glow type.................................................. 2-3
Manual glow type...................................................... 2-3
Water temperature meter and thermo unit....... 2-3
Ammeter........................................................... 2-4
Hour meter....................................................... 2-4
Stop solenoid ................................................... 2-4
RUN OFF (ETS: Energized To Stop) Type............... 2-4
RUN ON (ETR: Energized To Run) Type................. 2-4
Engine protection devices ...................2-5
Oil pressure switch........................................... 2-5
Thermo switch.................................................. 2-5
Air cleaner indicator ......................................... 2-5
Chapter 3
OPERATION
Preparations for operation...................3-1
External inspection........................................... 3-1
Inspecting the battery electrolyte level............. 3-1
Checking the fuel tank oil level......................... 3-2
Checking the engine oil level ........................... 3-2
Checking the coolant level............................... 3-3
Starting................................................3-4
Automatic grow plug......................................... 3-4
Manual grow plug............................................. 3-4
Warming-up operation.........................3-5
Checking engine oil pressure........................... 3-5
External inspection during warm-up................. 3-5
Operation.............................................3-6
Inspection during operation.............................. 3-6
Stopping ..............................................3-7
Inspection after stopping.................................. 3-7
Chapter 4
FUEL
Recommended fuel .............................4-1
Handling fuel........................................4-1
Chapter 5
ENGINE OIL
Properties of engine oil and
its influence on engine performance....5-1
Main properties of engine oil...............5-1
Dispersibility.....................................................5-1
Acid neutralization ability..................................5-1
Viscosity...........................................................5-1
Recommended engine oil...................5-2
Selection of oil viscosity......................5-2
Other brands of engine oil...................5-3
Handling engine oil .............................5-3
Service limits of engine oil ..................5-4
Definition of properties of engine oil....5-4
Viscosity...........................................................5-4
Total base number ...........................................5-4
Total acid number ............................................5-4
Water................................................................5-4
Flash point........................................................5-4
Insolubles.........................................................5-4
Chapter 6
COOLANT
Recommended water for coolant........6-1
Long life coolant (LLC)........................6-1
Genuine LLC.......................................6-1
Other brand LLCs ...............................6-2
Standard for other brand LLC.............6-2
General demands of LLC.................................6-2
LLC specification..............................................6-3
Maintenance of LLC............................6-6
Replacement intervals of LLC..........................6-6
LLC concentration............................................6-6
Importance of LLC ..............................6-7
Characteristics of LLC
additive and important notes...............6-7
Examples of abnormalities
caused by LLC....................................6-7
Pitting of iron parts ...........................................6-7
Corrosion of aluminum parts............................6-7
Pitting and clogging of the radiator...................6-7
Chapter 7
MAINTENANCE SCHEDULE
How to use the maintenance schedule7-1

CONTENTS
CONTENTS-3
Chapter 8
PERIODIC INSPECTION AND
MAINTENANCE PROCEDURES
Every 50 service hours........................8-1
Draining water from the fuel tank..................... 8-1
Checking the air cleaner .................................. 8-1
Every 100 service hours......................8-2
Checking and cleaning solenoid fuel pump filter8-2
Every 250 service hours......................8-3
Changing the engine oil and oil filter................ 8-3
Draining engine oil.................................................... 8-3
Changing the oil filter................................................ 8-4
Refilling engine oil..................................................... 8-5
Inspecting V-belt and adjusting belt tension..... 8-6
Inspecting V-belt....................................................... 8-6
Adjusting V-belt tension............................................ 8-6
Checking and cleaning the radiator fins........... 8-6
Every 400 service hours......................8-7
Changing fuel filter (Cartridge type)................. 8-7
Every 500 service hours......................8-8
Changing fuel filter element (Cock type).......... 8-8
Replacing solenoid fuel pump filter.................. 8-8
Every 1000 service hours....................8-9
Inspecting starters............................................ 8-9
Inspecting alternator......................................... 8-9
Every 2 years.....................................8-10
Changing the coolant..................................... 8-10
Draining the coolant................................................ 8-10
Cleaning the cooling system................................... 8-10
Refilling the coolant ................................................ 8-11
When required...................................8-12
Cleaning, inspecting, and replacing
the air cleaner element................................... 8-12
Bleeding the fuel system................................ 8-13
Bleeding the fuel filter (Cock type) ......................... 8-13
Bleeding the fuel filter (Cartridge type)................... 8-13
Bleeding water sedimenter..................................... 8-13
Draining water sedimenter............................. 8-14
Checking the specific gravity
of battery electrolyte....................................... 8-14
Chapter 9
LONG-TERM STORAGE
Long-term storage...............................9-1
Storing the engine in a non-operable
condition for 3 months or more...........9-1
Preparation for storage ....................................9-1
Recommended rust-preventive oil
and corrosion inhibitor ...............................................9-1
Maintenance during storage.............................9-1
Using the engine after storage.........................9-2
Storing the engine in an operable
condition for 3 months or more...........9-2
Operating the engine for maintenance.............9-2
Chapter 10
TRANSPORTATION
Lift the engine carefully.....................10-1
Chapter 11
TROUBLESHOOTING
General precautions..........................11-1
Contact your Mitsubishi dealer
for repair service ............................................11-1
Considerations before work ...........................11-1
Cautions against contamination.....................11-1
Cautions regarding parts handling .................11-1
Work safety ....................................................11-1
How to troubleshoot..........................11-2
The starter does not crank or cranks slowly,
resulting in start failure...................................11-2
The starter cranks, but the engine
does not start .................................................11-2
Other problems and countermeasures11-3
Engine output is low.......................................11-3
Exhaust smoke is white or blue .....................11-3
Exhaust smoke is black or dark gray..............11-4
Fuel consumption is high ...............................11-4
Engine oil consumption is high.......................11-4
Engine overheats ...........................................11-5
Engine oil pressure is faulty ...........................11-5
When fuel has run out.......................11-5

CONTENTS
CONTENTS-4
Chapter 12
MAIN SPECIFICATIONS
Main specifications............................12-1
List of Illustrations
Fig. 2-1 Engine left view(L2E).................................2-1
Fig. 2-2 Engine right view(L2E)...............................2-1
Fig. 2-3 Engine left view(L3C,L3E).........................2-2
Fig. 2-4 Engine right view(L3C,L3E).......................2-2
Fig. 2-5 Starter switch.............................................2-3
Fig. 2-6 Preheat indicator........................................2-3
Fig. 2-7 Water temperature meter and
thermo unit.................................................2-3
Fig. 2-8 Ammeter....................................................2-4
Fig. 2-9 Hour meter.................................................2-4
Fig. 2-10 Stop solenoid.............................................2-4
Fig. 2-11 Oil pressure switch ....................................2-5
Fig. 2-12 Thermo switch ...........................................2-5
Fig. 2-13 Air cleaner indicator...................................2-5
Fig. 3-1 Checking battery electrolyte level..............3-1
Fig. 3-2 Checking fuel level.....................................3-2
Fig. 3-3 Oil filler and oil level gauge........................3-2
Fig. 3-4 Radiator cap ..............................................3-3
Fig. 3-5 Radiator coolant level................................3-3
Fig. 3-6 Reserve tank coolant level.........................3-3
Fig. 4-1 Recommended fuel....................................4-1
Fig. 4-2 Recommended fuel according
to ambient temperature..............................4-1
Fig. 5-1 Recommended engine oil..........................5-2
Fig. 5-2 Recommended oil viscosity according
to ambient temperature..............................5-2
Fig. 6-1 GLASSY - LLC...........................................6-1
Fig. 8-1 Draining water from fuel tank.....................8-1
Fig. 8-2 Checking air element.................................8-1
Fig. 8-3 Checking and cleaning solenoid fuel
pump filter..................................................8-2
Fig. 8-4 Engine oil drain plug..................................8-3
Fig. 8-5 Changing oil filter.......................................8-4
Fig. 8-6 Oil filter.......................................................8-4
Fig. 8-7 Oil filler and oil level gauge........................8-5
Fig. 8-8 Tension adjusting V-belt............................8-6
Fig. 8-9 Cleaning radiator fins.................................8-6
Fig. 8-10 Changing fuel filter (cartridge type)............8-7
Fig. 8-11 Changing fuel filter element
(change cock type) ....................................8-8

CONTENTS
CONTENTS-5
Fig. 8-12 Changing solenoid fuel pump filter............ 8-8
Fig. 8-13 Checking starter........................................ 8-9
Fig. 8-14 Inspecting alternator ................................. 8-9
Fig. 8-15 Radiator cap............................................ 8-10
Fig. 8-16 Draining coolant (radiator) ...................... 8-10
Fig. 8-17 Draining coolant (engine main parts)...... 8-10
Fig. 8-18 Radiator .................................................. 8-11
Fig. 8-19 Reserve tank........................................... 8-11
Fig. 8-20 Removing air cleaner element................ 8-12
Fig. 8-21 Cleaning air cleaner element.................. 8-12
Fig. 8-22 Checking air cleaner element ................. 8-12
Fig. 8-23 Air cleaner indicator................................ 8-12
Fig. 8-24 Bleeding fuel filter (change cock type).... 8-13
Fig. 8-25 Bleeding fuel filter (cartridge type).......... 8-13
Fig. 8-26 Bleeding water sedimenter ..................... 8-13
Fig. 8-27 Draining water from sedimenter.............. 8-14
Fig. 8-28 Checking specific gravity
of battery electrolyte................................ 8-14
Fig. 10-1 Hangers for lifting.................................... 10-1
List of Tables
Table 3-1 Pre-heating duration
(automatic grow plug).............................3-4
Table 3-2 Pre-heating duration
(manual grow plug).................................3-4
Table 3-3 Standard values at rated speed .............3-6
Table 5-1 Service limit for engine oil properties .....5-4
Table 6-1 Water quality standards..........................6-1
Table 6-2 LLC specification....................................6-3
Table 6-3 Recommended LLC concentration.........6-6
Table 7-1 Maintenance schedule ...........................7-1
Table 8-1 Specific gravity of electrolyte................8-14
Table 9-1 Recommended rust-preventive oil
and corrosion inhibitor............................9-1
Table 11-1 The starter does not crank or
cranks slowly, resulting in start failure..11-2
Table 11-2 The starter cranks,
but the engine does not start................11-2
Table 11-3 Engine output is low.............................11-3
Table 11-4 Exhaust smoke is white or blue............11-3
Table 11-5 Exhaust smoke is black or dark gray....11-4
Table 11-6 Fuel consumption is high......................11-4
Table 11-7 Engine oil consumption is high.............11-4
Table 11-8 Engine overheats .................................11-5
Table 11-9 Engine oil pressure is faulty .................11-5
Table 12-1 Main specifications...............................12-1

1-1
Chapter 1 BASIC SAFETY PRECAUTIONS
Fire and explosion
Keep flames away
Store fuel and engine oil in a well
ventilated designated area.
Make sure that the caps of fuel and
engine oil containers are tightly
closed.
Do not use flames, do not smoke,
and do not work near a heater or other fire hazard
where fuel or oil is handled or when cleaning solvent
is being used for washing parts.
Wipe off spilled fuel, oil and LLC immediately and
thoroughly. Spilled fuel, oil and LLC may ignite and
cause a fire.
Keep engine surrounding area
tidy and clean
Do not leave combustible or explosive materials, such
as fuel, engine oil and LLC, near the engine. Such
substances can cause fire or explosion.
Remove dust, dirt and other foreign materials accu-
mulated on the engine and sorrounding parts thor-
oughly. Such materials can cause fire or the engine to
overheat. In particular, clean the top surface of the
battery thoroughly. Dust can cause a short-circuit.
Always operate the engine at a position at least 1 m
[3.28 ft.] away from buildings and other equipment to
prevent possible fire caused by engine heat.
Care for fuel, oil and exhaust
gas leakage
If any fuel, oil or exhaust gas leakage is found, imme-
diately take corrective measures to stop it.
Such leakages, if left uncorrected, can cause fuel or
engine oil to reach hot engine surfaces or hot exhaust
gas to contact flammable materials, possibly leading
to personal injury and/or damage to equipment.
Use explosion-proof lighting
apparatus
When inspecting fuel, engine oil, coolant, battery elec-
trolyte, etc., use a flameproof light. An ordinary light, if
accidentally broken, may ignite and cause an explo-
sion.
Prevent electrical wires from
short-circuiting
Avoid inspecting or servicing the electricalsystem with
the ground cable connected to the battery. Otherwise,
a fire could result from short-circuiting. Be sure to dis-
connect the battery cable from the negative (-) termi-
nal before beginning with the work procedure.
Short-circuits, possibly resulting in fire, may be
caused by a loose terminal or damaged cable/wire.
Inspect the terminals, cables and wires, and repair or
replace the faulty parts before beginning with the ser-
vice procedure.
Keep fire extinguishers and a
first-aid kit handy
Keep fire extinguishers handy, and
become familiar with their usage.
Keep a first-aid kit at the desig-
nated place where it is easily
accessiblebyanyoneatanytime.
Establish response procedures to
follow in the event of fire or accident. Provide an
emergency evacuation route and contact points and
means of communication in case of emergency.
:$51,1*

Chapter 1 BASIC SAFETY PRECAUTIONS
1-2
Stay clear of all rotating and moving parts
Install protective covers around
rotating parts
Make sure the protective covers of
the engine are correctly installed.
Repair any damaged or loose cov-
ers.
Never remove the protective cov-
ers of rotating parts during opera-
tion.
When the engine is coupled to the radiator or other
equipment, install protective covers around the
exposed connecting belt and coupling.
Never remove protective covers.
Check the work area for safety
Before starting the engine, make sure no one is near
the engine and tools are not left on or near the engine.
Verbally notify persons within the immediate area
when starting the engine.
When the starter device is posted with a sign that pro-
hibits startup operation, do not operate the engine.
Stay clear of moving parts dur-
ing engine running
Do not approach rotating or sliding
parts of the engine when the
engine is in operation.
Keep objects likely to be caught by
rotating parts away from such
parts.
If any part of the clothing or outfit-
ting is caught by a rotating part, serious bodily injuries
could result.
Lockout and Tagout
Be sure to lockout and tagout before starting inspec-
tion and maintenance.
Lockout and tagout are effective methods of cutting off
machines and equipment from energy sources.
To accomplish the lockout/tagout, remove the starter
switch key, set the battery switch to OFF and attach a
"Do Not Run" or similar caution tag to the starter
switch. The starter switch key must be kept by the per-
son who performs inspection and maintenance during
the work.
In the case of pneumatic starting type, close the main
valve of the air tank and post a tag saying "Do Not
Open the Valve" or the like.
Keep engine stopped during
servicing
Be sure to stop the engine before proceeding to
inspection and service procedure. Never attempt to
make adjustments on the engine parts while the
engine is running. Rotating parts such as belt can
entangle your body and cause serious injuries.
Always restore engine turning
tools after use
Do not forget to remove the tools which have been
used for turning the engine during inspection or ser-
vicing, after the procedure is finished. Remember also
that the turning gear must be returned to the operating
condition before starting the engine.
Starting the engine with the turning tools inserted or
with the turning gear in engagement can lead to not
only engine damage but also personal injuries.
Changing the engine speed set-
ting is prohibited
Never change engine speed setting.
Tampering with the setting can cause the engine and
its coupled machine to operate at excessive speeds
and result in accidents.
:$51,1*

Chapter 1 BASIC SAFETY PRECAUTIONS
1-3
Be careful of exhaust
fume poisoning
Operate the engine in a well-
ventilated area
If the engine is installed in an
enclosed area, and the exhaust
gas is ducted outside, ensure that
there is no exhaust gas leak from
duct joints.
When the engine is used for a
mobile generator set, never run the engine in an
enclosed area (such as a warehouse and tunnel), or
near the wall, structure, or equipment where the venti-
lation is bad. When the engine must be operated in an
enclosed area, provide sufficient ventilation, and dis-
charge exhaust gas to the outside. Make sure the
exhaust gas is not discharged directly to surrounding
buildings, plants or living passersby.
Exhaust gas from the engine contains carbon monox-
ide and other harmful substances. Operating the
engine in an ill-ventilated area can produce gas poi-
soning.
Protect ears from noises
Wear ear plugs
Always wear ear plugs when enter-
ing the machine room (engine
room). Combustion sound and
mechanicalnoise generated bythe
engine can cause hearing prob-
lems.
Be careful of falling down
Lift engine carefully
To lift the engine, always use a
correct wire rope capable of with-
standing the engine weight.
Attach the wire rope to the lifting
hangers provided on the engine
using a correct sling.
During lifting process, keep the
engine in a well-balanced position by taking the center
of gravity of the engine into consideration.
Keep the angle formed by slings attached to hangers
within 60 degrees. If the angle exceeds this limit,
excessive load could be imposed on the hangers and
this could damage the hangers and result in a serious
accident.
If the wire rope contacts the engine directly, place a
cloth or other soft padding to avoid damage to the
engine and wire rope.
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Chapter 1 BASIC SAFETY PRECAUTIONS
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Be careful of burns
Do not touch engine during or
immediately after operation
To avoid burns, do not touch the
engine during or immediately after
operation.
A hot engine can cause burns. To
conduct maintenance and inspec-
tion work, wait until the engine has
cooled sufficiently by checking the temperature
gauge.
Do not open the radiator filler
cap when the engine is hot
Never open the radiator filler cap while the engine is
running or immediately after the engine is stopped.
The engine coolant is hot during engine operation and
immediately after operation.
If the radiator filler cap is opened when the coolant is
at operating temperature, steam and hot coolant may
blow out and result in burns.
When opening the cap, stop the engine and allow the
coolant temperature to lower sufficiently. Cover the
cap with a cloth or use thick rubber glove, and then
slowly open the cap. When closing the cap, be sure to
tighten securely.
Add coolant only after the cool-
ant temperature dropped
Do not add coolant immediately after the engine
stops. Wait until the coolant temperature lowers suffi-
ciently to avoid a risk of burns.
Be careful of handling
fuel, engine oil and LLC
Use only specified fuel, engine
oil and long-life coolant (LLC)
Use fuel, oil and LLC specified in this manual, and
handle them carefully.
Use of any other fuel, oil or LLC, or improper handling
may cause various engine problems and malfunc-
tions.
Obtain the Material Safety Data Sheet (MSDS) issued
by the fuel, oil and LLC suppliers, and follow the direc-
tions in the MSDSs for proper handling.
Handle LLC (long life coolant)
carefully
When handling LLC, always wear rubber gloves and a
protective face mask. If LLC or cooling water contain-
ing LLC comes into contact with your skin oreyes, or if
it is swallowed, you would suffer from inflammation,
irritation or poisoning.
Should LLC be accidentally swallowed, induce vomit-
ing immediately and seek medical attention. Should
LLC enter your eyes, flush them immediately with
plenty of water and seek medical attention. If LLC
splashes onto your skin or clothing, wash it away
immediately with plenty of water.
Keep flames away from LLC. The LLC can catch
flames, causing a fire.
Proper disposal of waste oil
and coolant (LLC)
Do not discharge waste engine oil or coolant into sew-
erage, river, lake or other similar places. Such a way
of disposal is strictly prohibited by laws and regula-
tions.
Dispose of waste oil, coolant and other environmen-
tally hazardous waste in accordance with the applica-
ble law and regulations, or consult a Mitsubishi dealer.
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Chapter 1 BASIC SAFETY PRECAUTIONS
1-5
Service battery
Handle the battery correctly
• Never use flames or allow
sparks to generate near the bat-
tery. The battery releases flam-
mable hydrogen gas and
oxygen gas. Any flames or
sparks in the vicinity could
cause an explosion.
• Do not use the battery the fluid level of which is low-
ered below the lower limit line. Sustained use of the
battery could result in an explosion.
• Do not short the battery terminals with a tool or
other metal object.
• When disconnecting battery cables, always remove
the cable from the negative (-) terminal first. When
reconnecting the cables, attach the cable to the pos-
itive (+) terminal first.
• Charge the battery in a well-ventilated area, with all
filling hole plugs removed.
• Make sure the cable clamps are securely installed
on the battery terminals. A loose cable clamp can
cause sparks that may result in an explosion.
• Before servicing electrical components or conduct-
ing electric welding, set the battery switch to the
[Open/OFF] position or disconnect the cable from
the negative (-) battery terminal to cut off the electri-
cal current.
• Electrolyte (battery fluid) contains dilute sulfuric
acid. Careless handling of the battery can lead to
the loss of sight and/or skin burns. Also, keep the
battery fluid off the mouth.
• Wear protective goggles and rubber gloves when
working with the battery (when adding water, charg-
ing, etc.).
• If electrolyte is spilled onto the skin or clothing,
immediately wash it away with lots of water. Use
soap to thoroughly clean.
• The battery fluid can cause blindness if splashing
into the eyes. If it gets into the eyes, immediately
flush it away with plenty of clean fresh water, and
seek immediate medical attention.
• If the battery fluid is accidentally swallowed, gargle
with plenty of water, then drink lots of water, and
seek immediate medical attention.
When abnormality occurs
Do not add coolant immediately
after a sudden stop due to over-
heating
If the engine stops suddenly or if you have no choice
but to stop the engine suddenly due to overheating, do
not add coolant immediately.
Adding water while the engine is hot can damage
parts such as cylinder heads due to a sudden drop of
temperature. Add coolant gradually after the engine
has completely cooled.
Avoid immediate restart after
abnormal stop
If the engine stops abnormally, do not restart the
engine immediately. If the engine stops with an alarm,
check and remedy the cause of the problem before
restarting. Sustained use of the engine without any
remedy could result in serious engine problems.
Avoid continuous engine oper-
ation at low oil pressure
If an abnormal engine oil pressure drop is indicated,
stop the engine immediately, and inspect the lubrica-
tion system to locate the cause. Continuous engine
operation with low oil pressure could cause bearings
and other parts to seize.
If the fan belt breaks, stop the
engine immediately
If the fan belt breaks, stop the engine immediately.
Continuous engine operation with the broken fan belt
could cause the engine to overheat and thereby the
coolant to boil into steam, which may gush out from
the reserve tank or radiator, and cause personal inju-
ries.
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Chapter 1 BASIC SAFETY PRECAUTIONS
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Other cautions
Never modify engine
Unauthorized modification of the engine will void the
manufacturer's warranty.
Modification of the engine may not only cause engine
damage but also produce personal injuries.
If there is a need to modify the engine, contact your
Mitsubishi dealer.
Never break the seals
To ensure proper engine operation, the fuel control
links are sealed to prevent accidental change of the
injection volume and rotation speed settings. Operat-
ing the engine without these seals in place can cause
the problems described below, and also invalidates
the warranty.
• Rapid wear of sliding and rotating parts
• Engine damage such as seizing of engine parts
• Considerably increased consumption of fuel and
lubricating oil
• Degradation of engine performance due to improper
balance between fuel injection volume and governor
operation or overrunning of the engine which could
result in a serious accident.
Perform all specified pre-opera-
tion inspections and periodic
inspections
Conduct the pre-operation inspections and periodic
inspections as described in this manual.
Failure to conduct the specified inspections may
cause various engine problems, damage to parts, and
serious accidents.
Break-in the engine
To break in new engines or overhauled engines, oper-
ate the engine at a speed lower than the rated speed
in a light load condition during the first 50 hours of
operation.
Operating new engines or overhauled engines in a
severe condition during the break-in period shortens
the service life of the engine.
Warm up the engine before use
When starting auxiliary devices, such as a water
heater and an engine oil priming pump, are not
installed, let the engine idle for 5 to 10 minutes before
operating the engine for work. Warm-up operation cir-
culates lubricants in the engine and contributes to a
longer service life and economical operation. Do not
conduct warm-up operation for prolonged period of
time.
Prolonged warm-up operation causes carbon build-up
in the cylinders that leads to incomplete combustion.
Never operate the engine in an
overloaded condition
If the engine shows an overloaded condition such as
black exhaust smoke, reduce the load immediately to
operate the engine at an appropriate output and load.
Overloading causes not only high fuel consumption
but also excessive carbon deposits inside the engine.
Carbon deposits cause various problems and will
shorten the service life of the engine.
Conduct cooling operation
before stopping the engine
Before stopping the engine, let it idle at low speed for
5 to 6 minutes to cool down.
Stopping the engine immediately after high-load oper-
ation will cause engine parts to heat up and shorten
the service life of the engine.
During cooling operation, check the engine for abnor-
malities.
Protection of the engine against
water entry
Do not allow rainwater, etc. to enter the engine
through the air inlet or exhaust openings.
Do not wash the engine while it is operating. Cleaning
fluid (water) can be sucked into the engine.
Starting the engine with water inside the combustion
chambers can cause the water hammer action which
may result in internal engine damage and serious
accidents.
&$87,21