Mitsubishi 4M40 Engine (CAT Machine) Service Repair Manual

4M40 Engine
Language English
Specific for CAT Machinery

Table of Content Mitsubishi 4M40 Engine

General
Engine Number, Engine Name Plate
How To Read This Manual
Structure of This Shop Manual
Terminology
Tightening Torques
Standard tightening torque table
Units
How To Read This Manual
General Work
Part Measurement Methods
Shaft-to-hole clearance measurement, and good/bad evaluation
Shaft deflection and bend
Measurement of springs
Evaluation of Oil Leakage
Precautions For Maintenance Operation
General Precautions
Precautions for Electrical System
Handling precautions for electric circuits
Precautions for Arc Welding
Engine
Specifications
Remarks
Structure And Operation
Exploded View
Cylinder Head and Cylinder Head Gasket
Cylinder head
Cylinder head gasket
Valve Mechanism and Timing Chain
Valve Mechanism
Timing Chain
Timing Gears
Idler Gear
Connecting Rods
Piston and Piston Rings
Flywheel
Crankcase, Crankshaft and Main Bearings
Crankcase
Crankshaft
Main Bearing
Thrust Plates
Oil Seal
Front Oil Seal
Rear Oil Seal
Troubleshooting
General Inspection And Adjustment
Measuring Compression Pressure
Service Standards
Inspection and Adjustment of Valve Clearances
Replacement of Timing Chain
Rocker Cover
Installation procedure
Cylinder Head And Valve Mechanism
Removal procedure
Installation procedure
Tightening procedure for bolts 1 to 18
Tightening procedure for bolts 19 and 20
Cylinder Head
Inspection before removal
Removal procedure
Inspection procedure
Refacing
Replacement of valve guides
Lapping
Refacing the valve seat
Replacement of valve seat
Installation procedure
Piston and Connecting Rod
Inspection before removal
Inspection procedure
Selection of oversize piston
Installation procedure
Removal procedure
Inspection procedure
Replacement of connecting rod bushing
Inspection procedure
Flywheel
Work before removal
Removal procedure
Installation procedure
Timing Gear Case
Installation procedure
Timing Gears
Inspection before removal
Inspection procedure
Installation procedure
Crankshaft and Crankcase
Inspection before removal
Removal procedure
Inspection procedure
Grinding of crankshaft
Installation procedure
Lubrication
Specifications
Structure and Operation
Lubrication System
Oil Pump
Oil Cooler and Oil Filter
Bypass valve
Regulator valve
Oil Filter <Engine-mounted Type>
Lubrication of Engine Components
Main bearing and connecting rod bearing
Valve mechanism
Check valves and oil jets
Idler shaft
Timing chain
Troubleshooting
General Inspection and Adjustment
Oil Filter Replacement
Engine-mounted type
Engine separately mounted type
Engine Oil Replacement
Engine Oil Leak Inspection
Oil Pan, Oil Strainer and Oil Jet
Installation procedure
Oil Pump
Inspection procedure
Oil Cooler
Oil Filter
Removal procedure
Inspection procedure
Installation procedure
Fuel and Engine Control
Specifications
Structure and Operation
Fuel System (Flow of Fuel)
Fuel Filter
Injection Nozzles
Injection Pump
Injection pump body
Governor
Automatic timer
Feed pump
Fuel-cut solenoid valve
Troubleshooting
General Inspection and Adjustment
Inspecting and Adjusting Fuel Injection Timing
Inspecting and Adjusting No-load Minimum and Maximum Speeds
Inspection of Fuel Leakage
Inspection of Injection Pipe and Fuel Pipe Mounting Clamp
Air-bleeding of Fuel System
Fuel Filter Replacement
Fuel Filter
Installation procedure
Injection Pump
Removal procedure
Installation procedure
Removal procedure
Installation procedure
Injection Nozzle
Inspection before removal
Removal procedure
Cleaning procedure
Inspection procedure
Cooling
Specifications
Structure And Operation
Cooling System (Flow of Coolant)
Thermostat
Water Pump
Troubleshooting
General Inspection And Adjustment
Inspection And Adjustment Of Belt Tension
Inspection of Belts
Coolant Replacement and Cleaning of Cooling System
Draining of Coolant
Cleaning Procedure
Air Bleeding of Cooling System
Air/Gas Leakage Test
Inspection of Coolant Leak
Coolant Fan, Belt And Water Pump
Water Hose And Pipe
Thermostat
Intake And Exhaust
Specifications
Structure And Operation
Air Cleaner
Turbocharger
Waste Gate Mechanism
Operating of Over-Boost Valve
Troubleshooting
General Inspection And Adjustment
Cleaning And Inspection Of Air Cleaner Element
Inspection Of Intake Manifold For Looseness
Inspection Of Exhaust Manifold For Cracks And Gas Leaks
Inspection Of Turbocharger For Cracks And Gas Leaks
Looseness Of Turbocharger
Air Cleaner
Turbocharger
Intake Manifold
Exhaust Manifold
Electrical
Specifications
Structure And Operation
Starter
Alternator
Circuit Diagram
Troubleshooting
Power And Charging
Engine Starting, Preheating and Stopping
#180 to #249 Relay, #250 to #349 Sensor, #750 to #859 Other
#187 Inspection of starter relay
#231 Inspection of safety relay
#262 Inspection of water temperature sensor
#764 Inspection of glow plug
#930 Starter
#940 Alternator
#950 Inspection Of Alternator
#951 Inspection Of Regulator
#955 Inspection Of Preheating System
#959 Inspection Of SafetyRelay