CONFIDENTIAL

Page 1 of 6
SERVICE BULLETIN CODE
DESCRIPTION 3 2003 096
FILING LOCATION

ZX All-246
SUBJECT JD All-222

OUT-OF-PLACE EC ANGLE SENSOR

OUTLINE

We investigated returned parts of the EC motors that were regarded as being damaged.
The survey revealed no abnormality of the EC motor itself but in most cases, the EC angle sensor
was displaced.
An out-of-place EC angle sensor can be repositioned so follow the instructions given in this service
bulletin.

Thoroughly read the safety section in the service manual before starting the work to ensure safe operation.
Welding work, if any, should only be done by qualified welders.

APPLICABLE MODELS / SERVICE BULLETIN NO. FOR EACH MODEL

Machine Model(s): ZX70~ZX800 Series/JD80C~JD800C Series

Service Bulletin No. For Each Model: Refer to the following page.
Machine Serial Nos.: Refer to the following page.

DESCRIPTION

Refer to the following page(s).

DWN
CHKD
SA/GI: ZX All-096 WHITE APPD
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Page 2 of 6
SERVICE BULLETIN CODE
DESCRIPTION 3 2003 096
FILING LOCATION

ZX All-246
JD All-222
FAILURE DESCRIPTION
1 The engine fails to stop.
2 The engine will not run at the speed set by the engine control dial.
(Example: Even when the engine control dial is set to FULL, the engine is not rotating at full speed.)

COUNTERMEASURES

In the event of any failure, trouble-shoot the system while referring to the flow chart given from the next page
onward.
If Engine Learn is made during this process, the lever remains displaced. This may cause the EC angle sensor to
slide, and thus you are unable to put a faulty shovel in order.
(We think that the products were returned because the above state was attributed to EC motor failure.)
Should the EC angle sensor be displaced, rectify it according to the instructions given from page 4 onward.
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Page 3 of 6
SERVICE BULLETIN CODE
DESCRIPTION 3 2003 096
FILING LOCATION

ZX All-246
TROUBLESHOOTING FLOW CHART JD All-222

· The engine fails to stop.
· The engine will not run at the speed set by the engine
control dial.
(Example: Even when the engine control dial is set to
FULL, the engine is not running at full speed.)
(A) When setting the engine control dial to any value,
does the EC motor speed increase or decrease
accordingly?
Note: If Engine Learn is made with the lever kept loose before
running (E) at the time of problem occurrence, the EC angle
sensor will be out of place.
In this case, perform readjustment in accordance with the
instructions given from page 3 onward. (It will be restored to the
former state through readjustment since no part has been
broken.)
However, if the controller has been replaced with the new one
during troubleshooting and Engine Learn has never been
successfully made, it is necessary to remove the motor and
connect it to other machine to solve the problem.

No (C) The harness, EC motor or controller may be defec

yes tive.
Use the Dr. EX to check the EC angle sensor (EC motor
angle sensor) for reading. Does the EC angle senor read
2.5V or so when returning the engine control dial to
idling position after having it moved up and down? (After
the engine speed is changed and when the engine
control dial is placed in the same position, does the EC
angle sensor read the same value as the previous one?)

yes No

(B) Turn the key off and wait for 10 minutes or more.
Is the EC motor link facing almost downward? The EC motor (EC angle sensor) may be defective.
(The motor is placed in relation to the link as shown
below.)

yes No

(E) Even if the link seems to be positioned in place, the (D) Start the engine, set the EC dial to idling speed,
screw may be loose. Check this and then follow step loosen the lever securing bolt on the EC motor,
(D). adjust the engine to run at idling speed, tighten the
lever securing bolt, and then start Engine Learn.

[Link installation location]

Must be positioned almost

perpendicularly

Hitachi P/No. 920725

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SERVICE BULLETIN CODE
DESCRIPTION 3 2003 096
FILING LOCATION

1 How to check for out-of-place EC angle sensor

ZX All-246
JD All-222
Measure the resistance of the EC angle sensor using a tester, as outlined below.

3-pole connector

① ② ③

If the resistance between 1 and 2 is almost the same as that between 2 and 3 , there will be no prob-
lem. (Because of variations in all resistances, we cannot give specific values such as within ± O Ω.)

Resistance between 1 and 2 (1.048 kΩ) Resistance between 2 and 3 (1.071 kΩ)

If the resistance between 1 and 2 is not almost the same as that between 2 and 3 , as shown below,
correct the position.

Resistance between 1 and 2 (1.705 kΩ) Resistance between 2 and 3 (0.439 kΩ)
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Page 5 of 6
SERVICE BULLETIN CODE
DESCRIPTION 3 2003 096
FILING LOCATION

ZX All-246
Even if the resistances between 1 and 2 and 2 and 3 cannot be mea- JD All-222
sured with OL, also correct the position.

Resistance between 1 and 2 (OL over range) Resistance between 2 and 3 (OL over range)

2 How to rectify the out-of-place EC motor EC angle sensor

The out-of-place EC angle sensor can be repositioned on the actual machine but, for the machine in which
no Engine Learn is terminated, repositioning cannot be made.
The method of repositioning with the motor unit is shown below. If, however, you loosen the lever tightening
bolt, repositioning can be made with the EC angle sensor attached on the actual machine.

1 Connect only the motor connector to the actual machine, and then turn the key ON.

Connect the connector

to the out-of-place motor,
and turn the key ON

Remove the connector

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Page 6 of 6
SERVICE BULLETIN CODE
DESCRIPTION 3 2003 096
FILING LOCATION

ZX All-246
JD All-222
2 Turn the key OFF, the motor will move and stop for 4 seconds. It will then reverse and stop. Remove the 4-pole
connector while the motor is at a stop for 4 seconds.

After turning the key OFF, The motor is at a stop for 4 seconds. The motor will reverse, and then stop.
the motor will move.

Remove the 4-pole connector

while the motor is at a stop

2 After about 10 seconds, connect the connector again and turn the key ON.
3 Turn the key OFF, the motor will move and stops for 4 seconds, and then reverse and stop.

The EC angle sensor will be centered (2.5V) through the above steps. However, if the EC angle sensor is signifi-
cantly displaced, you may repeat steps 2 and 3 several times.
Tighten the lever tightening bolt so that the engine will run at idling speed with the EC angle sensor positioned as
corrected.