Replacing the EGR (Exhaust Gas Recirculation) valve on a HITACHI EX100 or EX100M Hydraulic Excavator requires some basic mechanical understanding and tools. click here for more details on the download manual…..
- General service Exavator EX 100-1
- Hitachi EX100M Hydraulic Excavator
Here’s a simplified step-by-step guide to help you through the process:
### Tools and Materials Needed:
– New EGR valve
– Wrenches and sockets (typically metric)
– Screwdrivers (flathead and Phillips)
– Pliers
– Clean rags
– Engine oil (for threads)
– safety gloves and goggles
### safety Precautions:
1. **Turn Off the Excavator**: Ensure the engine is off and the keys are removed.
2. **Allow Engine to Cool**: Wait for the engine to cool down to avoid burns.
3. **Wear safety Gear**: Use gloves and goggles to protect yourself.
### Steps to replace the EGR Valve:
1. **Locate the EGR Valve**:
– Open the engine compartment of the excavator.
– The EGR valve is usually mounted on or near the engine, connected to the exhaust system and intake manifold. Look for a small cylindrical or rectangular component with pipes connected to it.
2. **Disconnect the Battery**:
– Before working on any electrical components, disconnect the negative terminal of the battery to prevent shocks or short circuits.
3. **Remove the EGR Valve**:
– **Disconnect the Pipes**: Use a wrench to loosen and remove the bolts or clamps securing the pipes to the EGR valve. Be cautious, as some exhaust gases may still be hot.
– **Unplug Electrical Connectors**: If your EGR valve has any electrical connections, carefully unplug them.
– **Unbolt the EGR Valve**: Use the appropriate socket or wrench to remove the bolts holding the EGR valve in place. Keep these bolts as you will need them for the new valve.
– **Take Out the Old Valve**: Gently pull the EGR valve away from its mounting location.
4. **Prepare for New Valve Installation**:
– **Clean the Mounting Surface**: Use a rag to clean the area where the EGR valve was mounted. Make sure there are no old gasket remnants or debris.
– **Inspect Gaskets**: If your new EGR valve does not come with a gasket, you may need to replace the old one. Make sure to use a new gasket to ensure a proper seal.
5. **Install the New EGR Valve**:
– **Position the New Valve**: Place the new EGR valve onto the mounting surface.
– **Bolt It Down**: Hand-tighten the bolts first, then use a wrench to secure them. Be careful not to overtighten, as this can damage the valve or the manifold.
– **Reconnect the Pipes**: Reattach the pipes and secure them with the clamps or bolts you removed earlier.
– **Plug in Electrical Connectors**: If applicable, reconnect any electrical connectors to the EGR valve.
6. **Reconnect the Battery**:
– Reattach the negative terminal of the battery.
7. **Test the Excavator**:
– Start the engine
and let it warm up for a few minutes. Check for any leaks around the new EGR valve and ensure it runs smoothly.
– If you encounter any warning lights on the dashboard or unusual sounds, turn off the engine and double-check your connections.
### Final Checks:
– After the installation, monitor the excavator during operation for any signs of issues.
– If you notice any problems, consult a professional mechanic for further assistance.
### Conclusion:
Replacing the EGR valve on a HITACHI EX100 or EX100M Hydraulic Excavator is a manageable task with proper tools and care. Following this guide should help you successfully complete the replacement. Always refer to the specific service manual for detailed information and specifications related to your excavator model.
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