Kawasaki Wheel Loader ZX490 7 Operational & Service Manual & Parts Manual

Description

Kawasaki Wheel Loader ZX490 7 Operational & Service Manual & Parts Manual 

File Details:

Kawasaki Wheel Loader ZX490 7 Operational & Service Manual & Parts Manual 

Language : English
Pages : 500+
Size : 153 MB
Downloadable : Yes
Format : PDF

KAWASAKI WHEEL LOADER ZX490 7 OPERATIONAL & SERVICE MANUAL & PARTS MANUAL:

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Table of Contents:

Kawasaki Wheel Loader ZX490 7 Operational & Service Manual & Parts Manual 

Specifications Specifications Specifications ……………………………………..T1-1-1
Specifications ZX490LCH-7……………………………………….T1-1-1
Working Ranges ZX490LCH-7…………………………………..T1-1-2
Component Layout……………………………..T1-2-1
Main Component (Upperstructure)…………………………T1-2-1
Main Component (Undercarriage)…………………………..T1-2-3
Main Component (Front Attachment)…………………….T1-2-3
Electrical System (Overview)…………………………………….T1-2-4
Electrical System (Rear Tray)……………………………………..T1-2-5
Electrical System (Switches)………………………………………T1-2-6
Electrical System (Utility Space)……………………………….T1-2-7
Electrical System (Around Battery)…………………………..T1-2-7
Engine Oil Monitoring Sensor…………………………………..T1-2-8
Hydraulic Oil Monitoring Sensor………………………………T1-2-8
Engine…………………………………………………………………………..T1-2-9
Aftertreatment Device……………………………………………..T1-2-10
Pump Device……………………………………………………………..T1-2-11
Around Pump Device……………………………………………….T1-2-11
Control Valve……………………………………………………………..T1-2-12
Signal Control Valve………………………………………………….T1-2-12
Pilot Check Valve……………………………………………………….T1-2-13
Swing Device……………………………………………………………..T1-2-14
Travel Device……………………………………………………………..T1-2-14
4-Spool Solenoid Valve Unit (Control Valve Side)……………………………………………………………………………………T1-2-14
4-Spool Solenoid Valve Unit (Hydraulic Oil Tank Side)………………………………………………………………………..T1-2-15
Expansion Tank………………………………………………………….T1-2-15
Air Cleaner………………………………………………………………….T1-2-16
DEF Tank……………………………………………………………………..T1-2-16
DEF Supply Module…………………………………………………..T1-2-17
Coolant Control Valve……………………………………………….T1-2-17
Around Radiator………………………………………………………..T1-2-18
Shockless Valve………………………………………………………….T1-2-18
Fan Valve…………………………………………………………………….T1-2-19
Layout of Attachment Specification Parts…………….T1-2-19
Around Control Valve……………………………………………….T1-2-20
Control Valve Lower Side…………………………………………T1-2-20
Boom Upper Area……………………………………………………..T1-2-21
Arm Upper Area…………………………………………………………T1-2-21
Distribution Valve (Upperstructure)……………………….T1-2-22
Component Specifications Specifications Specifications …………………..T1-3-1
Specifications of Engine…………………………………………….T1-3-1
Specifications of Engine Accessories……………………….T1-3-2
Specifications of Hydraulic Component………………….T1-3-3
Specifications of Electrical Component…………………..T1-3-4
TOJAQ51-EN-00(16/01/2020)
MEMO
TOJAQ51-EN-00(16/01/2020)
2
SYSTEM
Controller…………………………………………..T2-1-1
Outline of Controller…………………………………………………..T2-1-1
CAN Circuit…………………………………………………………………..T2-1-1
Control System……………………………………T2-2-1
Outline of Control System…………………………………………T2-2-1
Engine Control…………………………………………………………….T2-2-1
Engine Control System Layout………………………………….T2-2-2
Engine Protection Control…………………………………………T2-2-3
Engine Control Dial Control………………………………………T2-2-5
ECO Control………………………………………………………………….T2-2-7
Power Mode (ECO/PWR/HP Mode) Switch Control…………………………………………………………………………………..T2-2-9
ECO/PWR Mode Travel Speed Increase Control……T2-2-11
Auto-Idle Control………………………………………………………T2-2-13
Radiator Coolant Temperature Auto-Warming Up Control……………………………………………………………………T2-2-15
Engine Speed Slow Down Control…………………………T2-2-17
One-Touch Idle Control (Option)…………………………….T2-2-19
Pump Control…………………………………………………………….T2-2-21
Pump Control System Layout………………………………….T2-2-22
Pump Flow Rate Control………………………………………….T2-2-23
Engine Control Dial Output Control……………………….T2-2-25
Speed Sensing Control…………………………………………….T2-2-27
Output Power Control………………………………………………T2-2-30
ECO/PWR Mode Control…………………………………………..T2-2-32
Relief Flow Rate Decrease Control………………………….T2-2-34
Swing High Pressure Power Decrease Control……..T2-2-36
Overheat Prevention Control………………………………….T2-2-38
Attachment Operation Pump Control (Option)……T2-2-40
Fan Pump Flow Rate Control (Air Conditioner Switch: OFF)…………………………………………………………..T2-2-42
Fan Pump Flow Rate Control (Air Conditioner Switch: ON)……………………………………………………………T2-2-44
Pump and Valve Learning Control………………………….T2-2-46
Pump Torque Restriction Control…………………………..T2-2-48
Valve Control (Standard)………………………………………….T2-2-50
Valve Control (Standard) System Layout……………….T2-2-51
Pressure Rising Selection Control When Traveling………………………………………………………………………………….T2-2-52
Power Digging Control…………………………………………….T2-2-54
Auto-Power Lift Control……………………………………………T2-2-56
Travel Motor Displacement Angle Control……………T2-2-58
Boom Mode Selector Control………………………………….T2-2-60
Swing Flow Rate Control………………………………………….T2-2-62
Arm 2 Flow Rate Control………………………………………….T2-2-64
Bucket Flow Combiner Control……………………………….T2-2-66
Aftertreatment Device Manual Regeneration Control……………………………………………………………………T2-2-68
Aftertreatment Device Auto Regeneration Control…………………………………………………………………………………T2-2-70
Engine Protection Control at Low Temperature…..T2-2-72
Radiator, Oil Cooler Fan Reverse Rotation Control………………………………………………………………………………….T2-2-74
Arm Regenerative Cut Control………………………………..T2-2-76
Valve Control (Option)……………………………………………..T2-2-78
Valve Control (Option) System Layout…………………..T2-2-79
Auxiliary Flow Combiner Control……………………………T2-2-80
Breaker Circuit Connection Control……………………….T2-2-82
Auxiliary Overload Relief Valve Pressure Decrease Control……………………………………………………………………T2-2-84
Other Control…………………………………………………………….T2-2-86
Work Mode Control…………………………………………………..T2-2-86
Auto Shut-Down Control…………………………………………T2-2-87
Hydraulic Oil Overheat Alarm Control…………………..T2-2-88
Engine Oil, Coolant Level Check Control……………….T2-2-89
Auto-Lubrication Control (Option)…………………………T2-2-90
Breaker Alarm Control (Option)………………………………T2-2-91
Travel Alarm Control (Option)…………………………………T2-2-92
Overload Alarm Control (Option)……………………………T2-2-94
Engine System……………………………………T2-3-1
Outline of ECM System………………………………………………T2-3-1
Fuel Injection Control…………………………………………………T2-3-2
Fuel Injection Amount Control…………………………………T2-3-3
Fuel Injection Timing Control……………………………………T2-3-6
Fuel Injection Rate Control………………………………………..T2-3-8
Fuel Injection Pressure Control…………………………………T2-3-9
Fuel Injection Amount Correction Control……………T2-3-11
EGR Control………………………………………………………………..T2-3-13
Preheating Control……………………………………………………T2-3-15
Variable Turbocharger Control……………………………….T2-3-16
Alarm Control…………………………………………………………….T2-3-17
Urea SCR System……………………………………………………….T2-3-17
DEF Injection Control……………………………………………….T2-3-18
Start-Up Control………………………………………………………..T2-3-19
DEF Defrosting Control…………………………………………….T2-3-20
DEF Thermal Control………………………………………………..T2-3-21
After-Run Control………………………………………………………T2-3-23
Engine Output Restriction Control (INDUCEMENT)…………………………………………………………………………………T2-3-24
TOJAQ51-EN-00(16/01/2020)
InsufficientInsufficient Insufficient DEF Level……………………………………………….T2-3-25
Malfunction of Urea SCR System/Malfunction of EGR System……………………………………………………………T2-3-25
Outline of Aftertreatment Device…………………………..T2-3-26
Operation of Aftertreatment Device………………………T2-3-27
Aftertreatment Device Regeneration Control………T2-3-29
Hydraulic System………………………………..T2-4-1
Outline of Hydraulic System……………………………………..T2-4-1
Pilot Circuit of Hydraulic System………………………………T2-4-1
Operation Control Circuit…………………………………………..T2-4-3
Pump Control Circuit (Refer to COMPONENT OPERATION/Pump Device.)………………………………….T2-4-4
Aftertreatment Device Regeneration Control Circuit (Refer to SYSTEM/Control System.)…………T2-4-5
Bucket Flow Combiner Circuit (Refer to SYSTEM/Control System.)……………………………………………………..T2-4-6
Valve Control Circuit (Refer to COMPONENT OPERATION/Control Valve.)………………………………….T2-4-7
Travel Motor Displacement Angle Control Circuit (Refer to COMPONENT OPERATION/Travel Device.)…………………………………………………………………..T2-4-10
Swing Parking Brake Release Circuit (Refer to COMPONENT OPERATION/Swing Device.)……….T2-4-12
Emergency Boom Lower Circuit (Refer to COMPONENT OPERATION/Others (Upperstructure).)…………………………………………………T2-4-13
Main Circuit of Hydraulic System……………………………T2-4-16
Neutral Circuit……………………………………………………………T2-4-18
Flow Combiner Circuit……………………………………………..T2-4-19
Relief Circuit……………………………………………………………….T2-4-21
Combined Operation Circuit…………………………………..T2-4-23
Flow Combiner Circuit……………………………………………..T2-4-25
Swing Flow Rate Control Circuit……………………………..T2-4-27
Arm Regenerative Cut Circuit………………………………….T2-4-29
Arm 1 Flow Rate Control Circuit……………………………..T2-4-31
Arm 2 Flow Rate Control Circuit……………………………..T2-4-33
Bucket Regenerative Cut Circuit……………………………..T2-4-35
Boom Lower Meter-In Cut Control…………………………T2-4-37
Boom Cylinder Bottom Pressure: High (With the Front Attachment above the Ground)………………T2-4-37
Boom Cylinder Bottom Pressure: Low (With Track Raised off the Ground)………………………………………..T2-4-39
Breaker/Crusher Circuit of Hydraulic System (Option)………………………………………………………………….T2-4-41
Auxiliary Flow Combiner Circuit……………………………..T2-4-42
Breaker Circuit……………………………………………………………T2-4-43
Auxiliary Overload Relief Valve Pressure Decrease Circuit……………………………………………………………………..T2-4-44
Radiator and Oil Cooler Fan Reverse Rotation Control Circuit……………………………………………………….T2-4-45
Electrical System…………………………………T2-5-1
Outline of Electrical System………………………………………T2-5-1
Main Circuit of Electrical System………………………………T2-5-1
Electric Power Circuit (Key Switch: OFF)………………….T2-5-1
CAN Circuit…………………………………………………………………..T2-5-3
Accessory Circuit (Key Switch: ACC)…………………………T2-5-4
Starting Circuit (Key Switch: START)…………………………T2-5-5
Charging Circuit (Key Switch: ON)……………………………T2-5-7
Alternator Operation………………………………………………….T2-5-8
Regulator Operation…………………………………………………..T2-5-9
Surge Voltage Prevention Circuit……………………………..T2-5-9
Pilot Shut-Off Shut-OffShut-OffShut-Off Circuit (Key Switch: ON)…………………..T2-5-10
Auto Shut-Down Circuit/Automatic Engine Stop Circuit at Low Temperature………………………………..T2-5-11
Engine Stop Circuit……………………………………………………T2-5-13
Emergency Stop Circuit……………………………………………T2-5-14
Monitor Circuit of Electrical System……………………….T2-5-16
Security Circuit…………………………………………………………..T2-5-17
Aerial Angle Circuit……………………………………………………T2-5-18
Control Lever Automatic Pilot Shut-Off Shut-OffShut-OffShut-Off Circuit…….T2-5-18
Seat Belt Reminder Circuit……………………………………….T2-5-19
Radio Circuit……………………………………………………………….T2-5-20
Air Conditioner Circuit……………………………………………..T2-5-21
Accessory Circuit……………………………………………………….T2-5-22
Work Light Circuit (Work Light: ON)……………………….T2-5-22
Work Light Circuit (Work Light, Work Light (Cab Upper), and Boom Light: ON)…………………………….T2-5-24
Wiper Circuit………………………………………………………………T2-5-26
Washer Circuit……………………………………………………………T2-5-28
Cab Light Circuit (Cab Light Switch: Door Interlocking Position (Key Switch: ON))…………….T2-5-30
Cab Light Circuit (Cab Light Switch: ON Position)……………………………………………………………………………………T2-5-31
TOJAQ51-EN-00(16/01/2020)
3
COMPONENT OPERATION
Pump Device………………………………………T3-1-1
Outline of Pump Device…………………………………………….T3-1-1
Outline of Main Pump………………………………………………..T3-1-1
Operational Principle of Main Pump……………………….T3-1-2
Increasing and Decreasing of Main Pump Delivery Flow Rate…………………………………………………………………T3-1-2
Outline of Regulator (For Main Pump)…………………….T3-1-3
Control by Pump Control Solenoid Valve (Minimum Flow Rate)…………………………………………….T3-1-4
Control by Pump Control Solenoid Valve (Increase of Flow Rate)……………………………………………………………T3-1-5
Control by Pump Control Solenoid Valve (Decrease of Flow Rate)…………………………………………T3-1-7
Outline of Pump Control Solenoid Valve………………..T3-1-8
Operation of Pump Control Solenoid Valve (When in Neutral)……………………………………………………………….T3-1-8
Operation of Pump Control Solenoid Valve (When Excited)…………………………………………………………………….T3-1-9
Outline of Fan Pump…………………………………………………T3-1-10
Operational Principle of Fan Pump………………………..T3-1-10
Increasing and Decreasing of Fan Pump Delivery Flow Rate……………………………………………………………….T3-1-11
Outline of Regulator (for Fan Pump)………………………T3-1-12
Control by Fan Pump Control Solenoid Valve (Minimum Flow Rate)…………………………………………..T3-1-13
Control by Fan Pump Control Solenoid Valve (Increase of Flow Rate)………………………………………..T3-1-14
Control by Fan Pump Control Solenoid Valve (Decrease of Flow Rate)……………………………………….T3-1-15
Outline of Pilot Pump……………………………………………….T3-1-17
Outline of Pump Delivery Pressure Sensor……………T3-1-17
Outline of Pump Displacement Control Pressure Sensor…………………………………………………………………….T3-1-17
Swing Device………………………………………T3-2-1
Outline of Swing Device…………………………………………….T3-2-1
Outline of Swing Reduction Gear…………………………….T3-2-1
Outline of Swing Motor……………………………………………..T3-2-2
Outline of Swing Parking Brake………………………………..T3-2-4
When Brake is Released of Swing Parking Brake……T3-2-4
When Brake is Applied of Swing Parking Brake……..T3-2-4
Outline of Valve Unit…………………………………………………..T3-2-5
Operation of Make-Up Valve…………………………………….T3-2-5
Outline of Swing Relief Valve…………………………………….T3-2-7
Low-Pressure Relief Operation (Shockless Function) of Swing Relief Valve……………………………T3-2-7
High-Pressure Relief Operation (Overload Prevention) of Swing Relief Valve………………………..T3-2-7
Control Valve………………………………………T3-3-1
Outline of Control Valve…………………………………………….T3-3-1
Components in Control Valve…………………………………..T3-3-2
Main Circuit of Control Valve…………………………………..T3-3-13
Pilot Operation Control Circuit of Control Valve…..T3-3-14
External Pilot Pressure Circuit of Control Valve…….T3-3-16
Operation of Flow Combiner Valve………………………..T3-3-17
Outline of Main Relief Valve…………………………………….T3-3-20
Relief Operation of Main Relief Valve…………………….T3-3-20
Pressure Increasing Operation of Main Relief Valve…………………………………………………………………………………T3-3-21
Outline of Overload Relief Valve (With Make-Up Function)……………………………………………………………….T3-3-22
Relief Operation of Overload Relief Valve……………..T3-3-22
Make-Up Operation of Overload Relief Valve……….T3-3-23
Outline of Boom Overload Relief Valve (Low Pressure)………………………………………………………………..T3-3-23
Relief Operation of Boom Overload Relief Valve (Low Pressure)……………………………………………………….T3-3-24
Make-Up Operation of Boom Overload Relief Valve (Low Pressure)…………………………………………….T3-3-25
Operation of Auxiliary Overload Relief Valve Pressure Decrease………………………………………………..T3-3-25
Make-Up Operation of Auxiliary Overload Relief Valve……………………………………………………………………….T3-3-26
Outline of Regenerative Valve…………………………………T3-3-27
Operation of Boom Regenerative Valve………………..T3-3-27
Outline of Bucket Regenerative Valve……………………T3-3-29
Operation When Performing Bucket Regenerative Operation………………………………………………………………T3-3-29
Operation When Performing Bucket Regenerative Cut Operation……………………………………………………….T3-3-30
Operation When Performing Arm Regenerative Operation………………………………………………………………T3-3-31
Operation When Performing Arm Regenerative Cut Operation……………………………………………………….T3-3-33
Outline of Anti-Drift Valve……………………………………….T3-3-36
Holding Operation of Anti-Drift Valve……………………T3-3-36
Releasing Operation of Anti-Drift Valve…………………T3-3-37
Outline of Flow Rate Control Valve…………………………T3-3-37
Normal Operation of Flow Rate Control Valve……..T3-3-38
TOJAQ51-EN-00(16/01/2020)
Flow Rate Control Operation of Flow Rate Control Valve……………………………………………………………………….T3-3-39
Outline of Boom Lower Meter-In Cut Valve…………..T3-3-41
Operation of Boom Lower Meter-In Cut Valve (With the Track off the Ground)…………………………T3-3-43
Operation of Boom Lower Meter-In Cut Valve (With the Front Attachment above the Ground)…………………………………………………………………………………T3-3-45
Operation of Auxiliary Flow Combiner Valve (Auxiliary Flow Combiner Valve: OFF)……………….T3-3-48
Operation of Auxiliary Flow Combiner Valve (Auxiliary Flow Combiner Valve: ON)………………..T3-3-49
Outline of Pump 1 Bypass Shut-Out Valve and Pump 2 Bypass Shut-Out Valve………………………….T3-3-51
Operation of Pump 1 Bypass Shut-Out Valve……….T3-3-52
Operation of Pump 2 Bypass Shut-Out Valve……….T3-3-54
Pilot Valve………………………………………….T3-4-1
Outline of Pilot Valve………………………………………………….T3-4-1
Outline of Front Attachment/Swing Pilot Valve…….T3-4-1
Outline of Travel Pilot Valve………………………………………T3-4-2
Outline of Auxiliary Pilot Valve………………………………….T3-4-2
Operation of Front Attachment/Swing and Travel Pilot Valves………………………………………………………………T3-4-3
When Front Attachment/Swing and Travel Pilot Valves are in Neutral (Output Curve: A to B)………T3-4-4
During Metering or Decompressing of Front Attachment/Swing and Travel Pilot Valves (Output Curve: C to D)…………………………………………..T3-4-6
Full Stroke of Front Attachment/Swing and Travel Pilot Valves (Output Curve: E to F)……………………….T3-4-8
Operation of Auxiliary Pilot Valve…………………………….T3-4-9
When Auxiliary Pilot Valve are in Neutral (Output Curve: A to B)…………………………………………………………..T3-4-9
During Metering or Decompressing of Auxiliary Pilot Valve (Output Curve: C to D)……………………..T3-4-10
Outline of Shockless Function (Only Travel Pilot Valve)……………………………………………………………………..T3-4-12
Operation of Shockless Function……………………………T3-4-12
Travel Device………………………………………T3-5-1
Outline of Travel Device…………………………………………….T3-5-1
Outline of Travel Reduction Gear……………………………..T3-5-2
Outline of Travel Motor………………………………………………T3-5-3
Operation of Travel Motor…………………………………………T3-5-3
Outline of Parking Brake……………………………………………T3-5-4
Operation of Parking Brake (When Parking Brake is Released)……………………………………………………………..T3-5-5
Operation of Parking Brake (When Parking Brake is Applied)……………………………………………………………….T3-5-6
Outline of Travel Brake Valve…………………………………….T3-5-7
Operation of Counterbalance Valve (During Travel)………………………………………………………………………T3-5-8
Operation of Counterbalance Valve (When Descending a Slope)……………………………………………..T3-5-9
Outline of Travel Relief Valve…………………………………..T3-5-11
Operation of Travel Relief Valve (During Relief)…..T3-5-11
Operation of Travel Relief Valve (During Make-Up)…………………………………………………………………………………T3-5-11
Outline of Travel Mode Control………………………………T3-5-13
Operation of Selecting Travel Mode (Slow Speed)………………………………………………………………………………….T3-5-13
Operation of Selecting Travel Mode (Fast Speed)……………………………………………………………………………………T3-5-13
Signal Control Valve……………………………T3-6-1
Outline of Signal Control Valve…………………………………T3-6-1
Pilot Valve Side of Pilot Port………………………………………T3-6-1
Control Valve Side of Pilot Port…………………………………T3-6-2
Outline of Shuttle Valve……………………………………………..T3-6-3
Outline of Shockless Valve…………………………………………T3-6-6
Operation of Shockless Valve (During Boom Raise Operation)……………………………………………………………….T3-6-6
Operation of Shockless Valve (During Boom Lower Operation or When Stopping Boom Raise Operation (Shock Reducing Operation))……………………………………………………………………………………..T3-6-7
Operation of Flow Combiner Valve Control Spool…………………………………………………………………………………….T3-6-9
Operation of Swing Parking Brake Release Spool……………………………………………………………………………………T3-6-10
Operation of Arm Flow Rate Control Valve Control Spool………………………………………………………………………T3-6-10
Others (Upperstructure)……………………..T3-7-1
Outline of Pilot Shut-Off Shut-OffShut-OffShut-Off Solenoid Valve…………………T3-7-1
Pilot Shut-Off Shut-OffShut-OffShut-Off Lever: LOCK Position………………………….T3-7-2
Pilot Shut-Off Shut-OffShut-OffShut-Off Lever: UNLOCK Position…………………….T3-7-2
Outline of Solenoid Valve………………………………………….T3-7-3
Outline of 4-Spool Solenoid Valve Unit (Control Valve Side)……………………………………………………………….T3-7-3
Outline of 4-Spool Solenoid Valve Unit (Hydraulic Oil Tank Side)…………………………………………………………..T3-7-4
Outline of 3-Spool Auxiliary Control Solenoid Valve Unit (Option)………………………………………………..T3-7-4
Outline of Proportional Solenoid Valve…………………..T3-7-6
Operation of Proportional Solenoid Valve (When in Neutral)……………………………………………………………….T3-7-6
Operation of Proportional Solenoid Valve (When Excited)…………………………………………………………………….T3-7-6
Outline of Hose Rupture Valve………………………………….T3-7-7
Operation of Hose Rupture Valve (When Control Lever is in Neutral)…………………………………………………T3-7-7
Operation of Hose Rupture Valve (During Boom Lower Operation)…………………………………………………..T3-7-9
Outline of Fan Motor………………………………………………..T3-7-10
Outline of Fan Valve………………………………………………….T3-7-11
Relief Operation of Fan Valve………………………………….T3-7-11
Make-Up Operation of Fan Valve……………………………T3-7-12
Outline of Pilot Relief Valve……………………………………..T3-7-14
Outline of Recirculation Valve…………………………………T3-7-15
Outline of Shockless Valve……………………………………….T3-7-15
TOJAQ51-EN-00(16/01/2020)
Operation of Shockless Valve………………………………….T3-7-16
Outline of Accumulator (Pilot Circuit)……………………T3-7-17
Outline of Accumulator (Low Pressure and High Pressure)………………………………………………………………..T3-7-18
Outline of Selector Valve………………………………………….T3-7-19
Operation of Selector Valve: OFF (Crusher)…………..T3-7-19
Operation of Selector Valve: ON (Breaker)…………….T3-7-20
Outline of Distribution Valve…………………………………..T3-7-21
Operation of Distribution Valve………………………………T3-7-21
Others (Undercarriage)……………………….T3-8-1
Outline of Swing Bearing…………………………………………..T3-8-1
Outline of Center Joint……………………………………………….T3-8-1
Outline of Track Adjuster…………………………………………..T3-8-2
TOJAQ51-EN-00(16/01/2020)
MEMO
TOJAQ51-EN-00(16/01/2020)
1
GENERAL
Specifications Specifications Specifications ……………………………………..T1-1-1
Specifications ZX490LCH-7……………………………………….T1-1-1
Working Ranges ZX490LCH-7…………………………………..T1-1-2
Component Layout……………………………..T1-2-1
Main Component (Upperstructure)…………………………T1-2-1
Main Component (Undercarriage)…………………………..T1-2-3
Main Component (Front Attachment)…………………….T1-2-3
Electrical System (Overview)…………………………………….T1-2-4
Electrical System (Rear Tray)……………………………………..T1-2-5
Electrical System (Switches)………………………………………T1-2-6
Electrical System (Utility Space)……………………………….T1-2-7
Electrical System (Around Battery)…………………………..T1-2-7
Engine Oil Monitoring Sensor…………………………………..T1-2-8
Hydraulic Oil Monitoring Sensor………………………………T1-2-8
Engine…………………………………………………………………………..T1-2-9
Aftertreatment Device……………………………………………..T1-2-10
Pump Device……………………………………………………………..T1-2-11
Around Pump Device……………………………………………….T1-2-11
Control Valve……………………………………………………………..T1-2-12
Signal Control Valve………………………………………………….T1-2-12
Pilot Check Valve……………………………………………………….T1-2-13
Swing Device……………………………………………………………..T1-2-14
Travel Device……………………………………………………………..T1-2-14
4-Spool Solenoid Valve Unit (Control Valve Side)……………………………………………………………………………………T1-2-14
4-Spool Solenoid Valve Unit (Hydraulic Oil Tank Side)………………………………………………………………………..T1-2-15
Expansion Tank………………………………………………………….T1-2-15
Air Cleaner………………………………………………………………….T1-2-16
DEF Tank……………………………………………………………………..T1-2-16
DEF Supply Module…………………………………………………..T1-2-17
Coolant Control Valve……………………………………………….T1-2-17
Around Radiator………………………………………………………..T1-2-18
Shockless Valve………………………………………………………….T1-2-18
Fan Valve…………………………………………………………………….T1-2-19
Layout of Attachment Specification Parts…………….T1-2-19
Around Control Valve……………………………………………….T1-2-20
Control Valve Lower Side…………………………………………T1-2-20
Boom Upper Area……………………………………………………..T1-2-21
Arm Upper Area…………………………………………………………T1-2-21
Distribution Valve (Upperstructure)……………………….T1-2-22
Component Specifications Specifications Specifications …………………..T1-3-1
Specifications of Engine…………………………………………….T1-3-1
Specifications of Engine Accessories……………………….T1-3-2
Specifications of Hydraulic Component………………….T1-3-3
Specifications of Electrical Component…………………..T1-3-4
TOJAQ51-EN-00(16/01/2020)

Description:

Kawasaki Wheel Loader ZX490 7 Operational & Service Manual & Parts Manual 

• To The Reader This manual is written for an experienced technician to provide technical information needed to maintain and repair this machine. The machine specification and description according to destination may be explained on this manual.
• ● Be sure to thoroughly read this manual for correct product information and service procedures. ● If you have any questions or comments, at if you found any errors regarding the contents of this manual, please contact using “Service Manual Revision Request Form” at the end of this manual. (Note: Do not tear off the form. Copy this form for usage.) • Service Material Development Center Hitach Construction Machinery Co., Ltd. • TEL: 81-29-832-9673 • FAX: 81-29-831-1162 • E-mail: [email protected] All information, illustrations and specifications in this manual are based on the latest product information available at the time of publication.
• The right is reserved to make changes at any time without notice. Additional References Please refer to the other materials (operator’s manual, parts catalog, engine technical material and Hitachi training material etc.) in addition to this manual. Manual Composition This manual consists the Technical Manual, the Workshop Manual and the Engine Manual. ● Information included in the Technical Manual: Technical information needed for redelivery and delivery
• • Operation and activation of all devices and systems, operational performance tests, and troubleshooting procedures. ● Information included in the Workshop Manual: Technical information needed for maintenance and repair of the machine
• • Tools and devices needed for maintenance and repair, maintenance standards, and removal / installation and assemble / disassemble procedures ● Information included in the Engine Manual: Technical information needed for redelivery and delivery and maintenance and repair of the machine • Operation and activation of all devices and systems, troubleshooting and assemble / disassemble procedures Page Number Each page has a number, located on the center lower part of the page. Each number contains the following information:

Please Note:

• This is the SAME exact manual used by your dealers to fix your vehicle.
• The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
• Any queries / doubts regarding your purchase, please feel free to contact [email protected]