The COGENG 4188762 is a premium direct OEM replacement throttle motor (engine speed control actuator) engineered for John Deere excavators ranging from the 490D to 992DLC models. This precision actuator controls engine RPM based on signals from the ECU or throttle lever, providing smooth and accurate speed control. Manufactured to meet or exceed original John Deere specifications, this throttle motor ensures reliable engine speed regulation, fast response, and long service life in demanding construction and mining environments.
| Specification Category | Technical Specifications |
|---|---|
| Compatible Excavator Models | EX100, EX150, EX160WD, EX200LC, EX270LC, EX300LC, EX400LC, EX700 |
| COGENG Part Number | CG-HIT-EX-TM-49 |
| Replaces OEM Part Number | 4188762 |
| Product Type | Heavy-Duty Throttle Motor Assembly |
| Operating Voltage | 12V/24V DC |
| Protection Rating | IP67 Sealed Connectors |
| Position Sensing | Integrated Position Sensor |
| Operating Temperature | -30°C to 85°C |
| Duty Cycle | 100% Continuous Duty Rated |
| Quality Assurance | 100% Performance and Vibration Tested |
| Warranty | COGENG 12-Month Warranty |
| Brand | Part Number |
|---|---|
| COGENG | 4188762 |
| John Deere | 4188762 |
| Hitachi | 4188762 (Interchange) |
| Interchange | 4188763, 4188764, AT438310, RE507236 |
| Parameter | Specification |
|---|---|
| Voltage Rating | 24V DC |
| Current Draw (idle) | 0.4 - 0.8 A |
| Current Draw (max load) | 2.0 - 3.5 A |
| Motor Type | DC servo motor |
| Duty Cycle | Intermittent / Continuous |
| Insulation Class | Class F (155°C) |
| Protection Rating | IP65 / IP67 |
| Electrical Connection | 4-pin or 5-pin Deutsch DT |
| Feedback Sensor | Integrated potentiometer (0-5V) |
| Parameter | Specification |
|---|---|
| Motor Type | Permanent magnet DC motor |
| Gear Train | Planetary gear reduction |
| Output Shaft Type | Splined / D-shaped |
| Rotation Angle | 0° - 75° (typical) |
| Torque Output | 3 - 6 Nm |
| Response Time | ≤ 0.5 sec (full range) |
| Housing Material | Aluminum die-cast |
| Mounting Interface | John Deere standard |
| Weight | 1.1 kg (2.4 lbs) |
| Dimensions (L×W×H) | 125 × 85 × 75 mm (approx.) |
| Parameter | Specification |
|---|---|
| Sensor Type | Potentiometer (rotary) |
| Supply Voltage | 5V DC (regulated) |
| Output Voltage Range | 0.5V - 4.5V |
| Resistance Range | 1kΩ - 5kΩ |
| Linearity | ±1% |
| Operating Angle | 0° - 75° (mechanical) |
| Parameter | Rating |
|---|---|
| Operating Temperature | -40°C to +85°C (-40°F to +185°F) |
| Storage Temperature | -40°C to +105°C (-40°F to +221°F) |
| Vibration Resistance | 15G @ 50-1000Hz |
| Shock Resistance | 40G |
| Ingress Protection | IP65 / IP67 |
| Corrosion Protection | Painted / Anodized finish |
Application / Compatibility
This throttle motor is designed for a wide range of John Deere excavators, specifically models from the 490D series up to the 992D LC series.
| Series | Example Models |
|---|---|
| 490D | 490D, 490D LC |
| 590D | 590D, 590D LC |
| 690D | 690D, 690D LC |
| 790D | 790D, 790D LC |
| 892D LC | 892D LC |
| 992D LC | 992D LC |
| Model | Series | Application |
|---|---|---|
| 490D | D-Series | Engine speed control |
| 490D LC | D-Series | Engine speed control |
| 590D | D-Series | Engine speed control |
| 590D LC | D-Series | Engine speed control |
| 690D | D-Series | Engine speed control |
| 690D LC | D-Series | Engine speed control |
| 790D | D-Series | Engine speed control |
| 790D LC | D-Series | Engine speed control |
| 890D | D-Series | Engine speed control |
| 890D LC | D-Series | Engine speed control |
| 992D | D-Series | Engine speed control |
| 992D LC | D-Series | Engine speed control |
| Model | Series | Application | Notes |
|---|---|---|---|
| 490E | E-Series | Engine speed control | Verify compatibility |
| 590E | E-Series | Engine speed control | Verify compatibility |
| 690E | E-Series | Engine speed control | Verify compatibility |
| 200D | D-Series | Engine speed control | Some models |
| 210D | D-Series | Engine speed control | Some models |
| 240D | D-Series | Engine speed control | Some models |
| 270D | D-Series | Engine speed control | Some models |
| 300D | D-Series | Engine speed control | Some models |
| 350D | D-Series | Engine speed control | Some models |
| 470D | D-Series | Engine speed control | Some models |
| Engine Model | Application | Notes |
|---|---|---|
| John Deere PowerTech 4045 | 490D-690D | Direct fit |
| John Deere PowerTech 6068 | 790D-992D | Direct fit |
| John Deere PowerTech Plus | Select models | Verify fitment |
Note: Verify with your equipment manual or contact COGENG with your machine serial number for exact compatibility confirmation.
⚠️ Note: Always verify compatibility with your specific machine serial number, as different engine configurations (e.g., Isuzu vs. John Deere PowerTech) may use different throttle actuators.
The throttle motor (also called a throttle actuator or governor actuator) is an electromechanical device that controls the engine speed (RPM) based on input from the operator and the engine control unit (ECU).
Remote Throttle Control:
Moves the engine fuel injection pump's throttle lever according to the operator's throttle dial position (idle to full RPM).
Auto-Idle Control:
Automatically reduces engine RPM to idle when no hydraulic functions are used for a preset time, saving fuel.
One-Touch Deceleration / Acceleration:
Allows the operator to instantly lower engine speed for short waiting periods or return to working speed.
Engine Protection (Depending on ECU programming):
May override operator input to reduce RPM if critical conditions (e.g., coolant overheat) are detected.
| Component | Function |
|---|---|
| Throttle Motor | Physically moves the fuel injection pump linkage to control engine speed |
| ECU / Controller | Sends PWM voltage signals to the motor based on throttle lever position |
| Feedback Potentiometer | Reports actual throttle position back to the ECU for closed-loop control |
| Return Spring | Provides fail-safe return to idle in case of electrical failure |
| Mode | Description | Motor Action |
|---|---|---|
| Idle | Engine at lowest RPM | Motor retracted / at rest position |
| Accelerating | Operator moves throttle lever | Motor extends to increase fuel |
| RPM Hold | Steady engine speed | Motor holds position (servo action) |
| Decelerating | Operator reduces throttle | Motor retracts to reduce fuel |
| Fail-safe | Electrical power loss | Return spring forces idle position |
| Pin | Function | Signal Type |
|---|---|---|
| Pin A (1) | Motor power (+) | 24V DC (PWM) |
| Pin B (2) | Motor power (-) | Ground |
| Pin C (3) | Position feedback signal | 0.5V - 4.5V DC |
| Pin D (4) | Feedback reference (GND) | 0V |
| Pin E (5) (if equipped) | Feedback supply (+5V) | 5V DC regulated |
⚠️ IMPORTANT: Pin configuration varies by application. Verify with your machine's electrical schematic before connecting.
| NO | Number | Name | Qty |
| 01 | 4187082 | LAMP;ROOM | 1 |
| 01A | 4187083 | .BULB | 1 |
| 20 | 4229055 | HARNESS;WIRE | 1 |
| 21 | 4229056 | HARNESS;WIRE | 1 |
| 61 | M430513 | SCREW | 2 |
| 62 | A590905 | WASHER;SPRING | 2 |
| 64 | 4188762 | Throttle Motor | 1 |
| 65 | 4188763 | WIPER-ARM | 1 |
| 65A | 4167472 | COVER | 1 |
| 66 | 4151077 | WIPER-BLADE | 1 |
| 67 | M500807 | .NUT | 1 |
| 68 | M430610 | SCREW | 3 |
| 69 | A590906 | WASHER;SPRING | 3 |
| 70 | A590106 | WASHER;PLANE | 3 |
| 72 | 4121152 | SPEAKER | 1 |
| 72A | 4210414 | SCREW | 4 |
| 73 | 4123177 | ANTENNA | 1 |
| 73A | 4210412 | SCREW | 1 |
| 73B | 4210413 | SCREW | 1 |
| Step | Action | Critical Note |
|---|---|---|
| Preparation | ||
| 1 | Park machine on level surface, lower bucket, engage parking brake | Safety first |
| 2 | Disconnect battery (negative first) | Electrical safety |
| 3 | Locate throttle motor on fuel injection pump | Consult service manual |
| 4 | Mark linkage position (TAKE A PHOTO) | Critical for calibration |
| Removal | ||
| 5 | Disconnect electrical connector | Inspect pins for damage |
| 6 | Remove linkage from throttle motor | Note orientation |
| 7 | Remove mounting bolts (usually 3 or 4) | Note bolt length/position |
| 8 | Remove old throttle motor | Discard properly |
| Installation | ||
| 9 | Compare new vs old (connector, shaft type) | Verify compatibility |
| 10 | Transfer mounting brackets (if applicable) | Use Loctite on threads |
| 11 | Install new throttle motor | Hand-tighten bolts first |
| 12 | Connect linkage in EXACT same position as old | Reference the photo |
| 13 | Torque mounting bolts to specification | 8-10 Nm (6-7 ft-lbs) |
| 14 | Reconnect electrical connector | Ensure fully seated, lock tab engaged |
| Final | ||
| 15 | Reconnect battery (positive last) | — |
| 16 | Perform throttle calibration | REQUIRED for proper operation |
| 17 | Start engine, test throttle from idle to full RPM | Verify smooth response |
Engine Runaway Prevention: An incorrectly calibrated throttle actuator can potentially command full engine speed upon startup. Before the first post-installation start, ensure the manual engine stop control is accessible and functional. Be prepared to shut down immediately. Keep bystanders clear of the machine.
Pinch and Entanglement Hazards: The actuator output arm and linkage move with considerable force and without warning when the throttle dial is adjusted or when auto-idle engages. Keep hands, fingers, and loose clothing well away from this area whenever the ignition is on.
Burn Risk: The injection pump, exhaust manifold, and surrounding engine castings operate at temperatures that can cause serious skin burns. Allow the engine to cool completely before working in this area, or wear appropriate heat-resistant protective gear.
Electrical Protection: Disconnect the battery before unplugging or plugging in the throttle actuator connector. Voltage transients during connection can damage the engine controller.
Mounting Integrity: A loose throttle actuator can cause intermittent and unpredictable engine speed changes. Apply a medium-strength thread-locking compound to mounting bolts if recommended. Recheck bolt torque after the first several operating hours.
| DTC | Description | Resolution |
|---|---|---|
| P0120 | Throttle position sensor circuit | Replace throttle motor |
| P0121 | Throttle position sensor range/performance | Replace throttle motor |
| P0122 | Throttle position sensor low input | Check wiring, replace motor |
| P0123 | Throttle position sensor high input | Replace throttle motor |
| P0125 | Throttle actuator control motor | Replace throttle motor |
| P0638 | Throttle actuator control range/performance | Replace throttle motor |
| P0698 | Throttle actuator control low voltage | Check power supply, replace motor |
| P0699 | Throttle actuator control high voltage | Check ECU, replace motor |
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