強鹿約翰迪爾John Deere柴油機氣缸蓋墊片故障通常分為哪幾類、診斷缸蓋墊片與更換方法

•燃燒密封故障。

•冷卻液密封故障。

•油封故障。

當燃燒氣體在氣缸蓋和氣缸蓋墊片燃燒法蘭之間或燃燒法蘭和氣缸套之間逸出時，會發生燃燒密封故障。泄漏的燃燒氣體可能排放到相鄰氣缸、冷卻液或油道或外部。

當機油或冷卻液在氣缸蓋和密封墊體之間或氣缸體和密封墊之間逸出時，會發生冷卻液或油封故障。油或冷卻液可能泄漏到相鄰的冷卻液或油道或外部。由于機油和冷卻液通道主要位于強鹿約翰迪爾John Deere柴油發動機的右側（凸輪軸），該區域最有可能發生油液泄漏。

發生或懷疑缸蓋墊片接頭故障時，請遵循以下診斷步驟。

1.在起動或拆卸強鹿約翰迪爾John Deere柴油發動機之前，對機器進行目視檢查，并注意以下任何情況：

•缸蓋墊片接縫或相鄰表面上的油或冷卻液。尤其是墊片接頭的右后角。

•墊片從正常位置的位移。

•燃燒氣體泄漏引起的變色或煙塵。

•散熱器、溢流箱或軟管泄漏。

•冷卻液從冷卻液泵泄漏孔泄漏。

•散熱器、風扇或護罩損壞或不正確。

•氣流或冷卻液流受阻。

•皮帶磨損或打滑。

•散熱器壓力蓋損壞或不正確。

•冷卻液中有油。

•冷卻液液位低。

•冷卻液不當。

•異常高或低油位。

•排氣系統中未燃燒的燃料或冷卻液。

•油降解、稀釋或污染。

氣缸蓋墊片接頭的診斷

A-燃燒密封區域B-油封區域（推桿）C-冷卻液密封區域D-氣缸蓋帶帽螺釘

E-油封區域（氣缸蓋帶帽螺釘）

•不正確指定的注射泵。

•燃油或正時調整指示。

2.獲取冷卻液和油樣進行進一步分析。

3.如果強鹿約翰迪爾John Deere柴油發動機能夠安全運行，則啟動并預熱強鹿約翰迪爾John Deere柴油發動機。按照概述再次檢查所有潛在泄漏區域

先前使用適當的測試和測量設備，檢查以下情況：

•白煙、過量的原燃料或排氣系統中的濕氣。

•粗糙、不規則的排氣聲或缺火。

•散熱器或溢流箱中的氣泡、氣體。

•溢出導致冷卻液損失。

•冷卻系統壓力過高。

•冷卻液過熱。

•冷卻液流量低。

•氣鎖（車輛強鹿約翰迪爾John Deere柴油發動機）導致駕駛室加熱損失。

4.關閉強鹿約翰迪爾John Deere柴油發動機。重新檢查曲軸箱、散熱器和溢流箱的液位、粘度或外觀是否有明顯差異。

5.將上述步驟的觀察結果與以下診斷圖表進行比較。

如果診斷評估和觀察提供了燃燒氣體、冷卻液或機油從缸蓋密封墊接頭泄漏的確鑿證據，則必須拆下缸蓋，以便檢查和修理密封墊接頭部件。

缸蓋墊片診斷圖

燃燒密封泄漏

癥狀和可能的原因

氣缸蓋墊片間隙排氣不足，襯套突出

散熱器/溢流箱中有氣泡，缸套過大，氣缸之間的壓差過大

溢流管的冷卻液排放低頭螺栓夾緊負載

強鹿約翰迪爾John Deere柴油發動機過熱、缸套法蘭表面粗糙/損壞

功率損失：燃燒法蘭墊片開裂/變形

強鹿約翰迪爾John Deere柴油發動機在平坦/損壞/粗糙的氣缸蓋表面上運行粗糙

白色排氣煙缺失/墊片防火環位置錯誤

駕駛室熱量損失（車輛強鹿約翰迪爾John Deere柴油發動機）氣缸體襯里支撐區域開裂

墊片部分移位、缺失（吹）或燃油輸送過量

氣缸內冷卻液提前噴射泵正時

曲軸箱機油中的冷卻液對燃燒密封的液壓或機械干擾

冷卻液液位低、冷卻系統泄漏或強鹿約翰迪爾John Deere柴油發動機過熱

氣缸蓋或缸套破裂也可能導致燃燒氣體泄漏到冷卻液中。

冷卻液密封泄漏

癥狀和可能的原因

冷卻液從氣缸蓋墊片間隙排出，缸套過度突出

曲軸箱機油中的冷卻液過多，缸套突出，氣缸之間的差速器

冷卻液液位低，螺栓夾緊負荷低

平坦/損壞/粗糙的缸體表面油位過高

冷卻液從曲軸箱通風口排出，氣缸蓋表面平整/損壞/粗糙，機油或冷卻液過熱

墊片體表面的裂紋/折痕、墊片彈性體卷邊的損壞/空隙

氣缸蓋、缸套、缸套填料破裂、機油冷卻器或后冷器故障也可能導致冷卻液泄漏到曲軸箱中。

油封泄漏

癥狀和可能的原因

油從缸蓋墊片間隙排出，襯套過度突出

冷卻液中油過多，缸套突出，氣缸間差速器

曲軸箱油位低，螺栓夾緊負荷低

從平坦/損壞/粗糙的缸體表面到搖臂的機油減少（噪音）

氣缸蓋表面不平整/損壞/粗糙、機油或冷卻液過熱

A-燃燒密封件（法蘭）、C-搖臂油柱、D-彈性體卷邊條、E-強鹿約翰迪爾John Deere柴油發動機前部、B-墊片體

建議采用以下檢查程序•相鄰車身區域燒傷/侵蝕。無論何時發生缸蓋墊片接頭故障，或當•火環斷開/移位/丟失時。

進行接頭拆卸。•法蘭密封模式偏心/包含空隙。

•法蘭和相鄰身體區域變色。

1.審查與機器•法蘭表面粗糙/磨損/溝槽相關的歷史數據。操作、維護和維修，以及診斷觀察。注意所有需要檢查墊片本體（B）的區域，以進行以下檢查和分析。

•燃燒氣體侵蝕路徑或煙塵沉積物

2.拆下搖臂蓋并檢查燃燒密封是否存在。

油中的冷卻液。•局部區域極度變色/硬化/脆化。

3.拆卸前記錄有頭螺釘扭矩。•端口區域（C）的O形密封圈缺失/損壞。拆卸后，檢查帶帽螺釘長度差異。•端口區域（D）中的彈性體缺失/損壞。

•來自端口區域的油或冷卻液路徑。

4.使用適當的起吊工具拆下氣缸蓋•局部低壓縮區域。防止處理損壞頭部的裝置墊片。請參閱拆卸氣缸蓋系列6。清潔部件前，檢查氣缸蓋、氣缸體和氣缸蓋，

本組中較早的數字（200000-）。以及燃燒氣體和流體證據的襯墊泄漏量檢查氣缸和閥口是否

5.觀察拆下的缸蓋墊片表面。不尋常的存款。

檢查燃燒密封件（A）是否存在以下情況：7.清潔缸體、缸蓋、襯套和帶帽螺釘。（這個組和組030）

•法蘭斷裂/膨脹/開裂/變形。

8.繼續進行以下尺寸檢查•檢查帶帽螺釘凸臺，必須清潔/完整。目視檢查：

氣缸套（030組）

氣缸蓋（本組）

•檢查襯里法蘭平面度/光潔度。

•檢查表面平整度/光潔度。•檢查襯里法蘭厚度（如果襯里已拆除）。

•檢查表面是否損壞。•檢查法蘭是否損壞。

•檢查氣缸蓋厚度，如果重新進行表面處理。

氣缸蓋帶帽螺釘（本組）

氣缸體和缸套（組裝和夾緊）（本組，030組。）•檢查是否存在腐蝕損壞。

•檢查螺紋狀況。

•檢查每個襯管上四個位置的襯管突出情況。•檢查直線度。

•檢查襯里與•檢查長度之間的顯著差異。氣缸。

9.檢查和測量完成后

氣缸體（組030.）完成，確定接頭故障的最可能原因。對接頭進行所有必要的修理

•檢查表面平整度/光潔度。部件、冷卻系統和燃油噴射

•檢查表面損壞。系統。

•檢查缸套沉孔深度（如果缸套

10.按照程序重新組裝強鹿約翰迪爾John Deere柴油發動機

•檢查頂部甲板至曲軸中心線以及該尺寸維修組中的規格。手冊。

Diagnosing Head Gasket Joint Failures Serial Number (200,000— )

Head gasket failures generally fall into three categories:

•       Combustion seal failures.

•       Coolant seal failures.

•       Oil seal failures.

Combustion seal failures occur when combustion gases escape between cylinder head and head gasket combustion flange, or between combustion flange and cylinder liner. Leaking combustion gases may vent to an adjacent cylinder, to a coolant or oil passage, or externally.

Coolant or oil seal failures occur when oil or coolant escapes between cylinder head and gasket body, or between cylinder block and gasket body. The oil or  coolant may leak to an adjacent coolant or oil passage, or externally. Since oil and coolant passages are primarily on right hand (camshaft) side of engine, fluid leaks are most likely to occur in that area.

Follow these diagnostic procedures when a head gasket joint failure occurs, or is suspected.

1.      Before starting or disassembling engine, conduct a visual inspection of machine, and note any of the following:

•       Oil or coolant in head gasket seam, or on adjacent surfaces. Especially right rear corner of gasket joint.

•       Displacement of gasket from normal position.

•       Discoloration or soot from combustion gas leakage.

•       Leaking radiator, overflow tank, or hoses.

•       Leaking coolant from coolant pump weep hole.

•       Damaged or incorrect radiator, fan, or shroud.

•       Obstructed air flow or coolant flow.

•       Worn or slipping belts.

•       Damaged or incorrect radiator pressure cap.

•       Presence of oil in coolant.

•       Low coolant levels.

•       Improper coolant.

•       Unusually high or low oil levels.

•       Unburned fuel or coolant in exhaust system.

•       Oil degradation, dilution, or contamination.

Diagnosing Cylinder Head Gasket Joints

A—Combustion Sealing Areas B—Oil Sealing Areas (Push Rod) C—Coolant Sealing Areas D—Cylinder Head Cap Screws

E—Oil Sealing Areas (Cylinder Head Cap Screws)

•       Incorrectly specified injection pump.

•       Indications of fuel or timing adjustments.

2.      Obtain coolant and oil samples for further analysis.

3.      Start and warm up engine if it can be safely operated. Examine all potential leakage areas again as outlined

previously. Using appropriate test and measuring equipment, check for the following:

•       White smoke, excessive raw fuel, or moisture in exhaust system.

•       Rough, irregular exhaust sound, or misfiring.

•       Air bubbles, gas trapped in radiator or overflow  tank.

•       Loss of coolant from overflow.

•       Excessive cooling system pressure.

•       Coolant overheating.

•       Low coolant flow.

•       Loss of cab heating due to air lock (vehicle  engines).

4.      Shut engine down. Recheck crankcase, radiator, and overflow tank for any significant differences in fluid levels, viscosity, or appearance.

5.      Compare your observations from above steps with the following diagnostic charts.

If diagnostic evaluations and observations provide conclusive evidence of combustion gas, coolant, or oil leakage from head gasket joint, the cylinder head must be removed for inspection and repair of gasket joint components.

Head Gasket Diagnostic Charts Serial Number (200,000— )

COMBUSTION SEAL LEAKAGE

Symptoms        Possible Causes

Exhaust from head gasket crevice  Insufficient liner standout

Air bubbles in radiator/overflow tank      Excessive liner standout differential between cylinders

Coolant discharge from overflow tube    Low head bolt clamping loads

Engine overheating Rough/damaged liner flange surface

Power loss        Cracked/deformed gasket combustion flange

Engine runs rough   Out-of-flat/damaged/rough cylinder head surface

White exhaust smoke      Missing/mislocated gasket fire ring

Loss of cab heat (vehicle engines)   Block cracked in liner support area

Gasket section dislodged, missing (blown)     Excessive fuel delivery

Coolant in cylinder   Advanced injection pump timing

Coolant in crankcase oil  Hydraulic or mechanical disturbance of combustion seal

Low coolant level     Leaks in cooling system or engine overheating

Cracked cylinder head or liners may also allow combustion gas leakage into coolant.

COOLANT SEAL LEAKAGE

Symptoms        Possible Causes

Coolant discharge from head gasket crevice  Excessive liner standout

Coolant in crankcase oil  Excessive liner standout differential between cylinders

Low coolant level     Low head bolt clamping loads

High oil level    Out-of-flat/damaged/rough block surface

Coolant discharge from crankcase vent Out-of-flat/damaged/rough cylinder head surface Oil or coolant overheating

Cracks/creases in gasket body surfaces Damage/voids in elastomer beading of gasket

Cracked cylinder head, liners, liner packings, defective oil cooler or aftercooler may also allow coolant leakage into  crankcase.

OIL SEAL LEAKAGE

Symptoms        Possible Causes

Oil discharge from head gasket crevice  Excessive liner standout

Oil in coolant    Excessive liner standout differential between cylinders

Low crankcase oil level    Low head bolt clamping loads

Reduced oil to rocker arms (noisy)  Out-of-flat/damaged/rough block surface

Out-of-flat/damaged/rough cylinder head surface Oil or coolant overheating

Cracks/creases in gasket body surfaces Damage/voids in elastomer beading of gasket

Damaged/missing O-ring seal at oil port to rocker  arms

Defective oil cooler may also allow oil leakage into  coolant.

Head Gasket Inspection and Repair Sequence Serial Number

A—Combustion Seals (Flange)         C—Rocker Arm Oil Columns    D—Elastomer Beading Strips E—Front of Engine B—Gasket Body

The following inspection procedures are recommended         •  Adjacent body area burned/eroded. whenever a head gasket joint failure occurs, or when    •  Fire ring severed/displaced/missing.

joint disassembly takes place.         •  Flange sealing pattern eccentric/contains voids.

•       Discoloration of flange and adjacent body areas.

1.      Review historical data relating to machine   •  Flange surfaces rough/abraded/channelled. operation, maintenance and repair, along with

diagnostic observations. Note all areas requiring  Examine gasket body (B) for the following: further inspection and analysis.

•       Combustion gas erosion paths or soot deposits

2.      Remove rocker arm cover and check for presence originating at combustion seals.

of coolant in the oil.          •  Extreme discoloration/hardening/embrittlement in localized areas.

3.      Record head cap screw torques prior to removal. •  O-ring seal missing/damaged in port area (C). Upon removal, check cap screw length differences.        •  Elastomer missing/damaged in port area (D).

•       Oil or coolant paths from port areas.

4.      Remove cylinder head using appropriate lifting      •  Localized areas of low compression. devices to prevent handling damage to head

gasket. See REMOVE CYLINDER HEAD SERIAL       6.  Before cleaning components, inspect head, block,

NUMBER (200,000— ) earlier in this group.   and liners for evidence of combustion gas and  fluid

leakage. Inspect cylinders and valve ports for

5.      Observe surfaces of removed head gasket.    unusual deposits.

Examine combustion seals (A) for the following:    7.  Clean block, head, liners, and cap screws. (This

group and Group 030.)

•       Flange severed/expanded/cracked/deformed.

8.      Proceed with the following dimensional checks and       •  Inspect cap screw bosses, must be clean/intact. visual inspections:

Cylinder Liner (Group 030.)

Cylinder Head (This group.)

•       Check liner flange flatness/finish.

•       Check surface flatness/finish. •  Check liner flange thickness (if liner is  removed).

•       Inspect for surface damage.   •  Inspect flange for damage.

•       Check cylinder head thickness, if resurfacing.

Cylinder Head Cap Screws (This group.)

Cylinder Block and Liners (assembled and

clamped) (This group, Group 030.) •  Inspect for corrosion damage.

•       Inspect condition of threads.

•       Check liner standout at four places on  each liner.        •  Inspect for straightness.

•       Check liner standout difference between        •  Check length. cylinders.

9.  When inspections and measurements have been

Cylinder Block (Group 030.)     completed, determine most probable causes of joint failure. Make all necessary repairs to joint

•       Check surface flatness/finish. components, cooling system, and fuel injection

•       Inspect for surface damage.   system.

•       Check liner counterbore depth (if liner is

removed).         10.  Reassemble the engine according to procedures

•       Check top deck to crankshaft centerline          and specifications in the repair groups of this dimension.      manual.

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