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E3170015B

This service bulletin provides revisions to a previous service bulletin regarding adding a new function to rewrite software on mobile line terminals for various excavator and wheel loader models. The revisions include replacing screenshots and adding an error message screenshot. Pages 22 and 23 of the previous service bulletin should be replaced. Procedures for rewriting the terminal software using MaintenancePRO Dr. are described over multiple pages.
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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100% found this document useful (1 vote)
293 views44 pages

E3170015B

This service bulletin provides revisions to a previous service bulletin regarding adding a new function to rewrite software on mobile line terminals for various excavator and wheel loader models. The revisions include replacing screenshots and adding an error message screenshot. Pages 22 and 23 of the previous service bulletin should be replaced. Procedures for rewriting the terminal software using MaintenancePRO Dr. are described over multiple pages.
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 44

SERVICE BULLETIN CODE

DESCRIPTION
3 2017 0015B
FILING LOCATION

SUBJECT ZX-5-All-226,
ZX-6-All-204
NEW FUNCTION ADDED TO MPDR. FOR REWRITING THE (Revised)
SOFTWARE ON THE MOBILE LINE TERMINALS (HPRO) IN THE
ZX-1/3/5/6, ZH-5/6, ZXW-5/6, AND ZW-5/6
REVISED
CORRECTION OF ERRORS

There are several corrections in Service Bulletin 3 2017 0015A which we previously issued.
Please replace Service Bulletin 3 2017 0015A with the attached revised version.

[Reason for revision of the Service Bulletin]


Some changes have been made to the screenshots because the procedures for setting the
terminal type in forced rewrite were changed.*1
Note: *1 The procedures were changed such that the terminal type and part number should
be entered in place of selecting the region.
Pages 22 to 23
- Three changes
Some screenshots have been replaced because the Forced Rewrite Setting Screen was
revised.
A screenshot of an error dialog has been added as an error message was added.

[Pages to be replaced]
22 and 23

CHKD
APPD
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ZX-5-All-226,
SUBJECT ZX-6-All-204
(Revised)
NEW FUNCTION ADDED TO MPDR. FOR REWRITING THE SOFTWARE
ON THE MOBILE LINE TERMINALS (HPRO) IN THE ZX-1/3/5/6, ZH-5/6, ZXW-5/6, AND ZW-5/6

OUTLINE
MaintenancePRO Dr. now has a function for rewriting the software on mobile line terminals (HPRO).
Rewrite the mobile line terminal software in accordance with this procedure.

Remove the rear trays. Use MPDr. to rewrite the software on the terminals.
For specific procedures, see the following pages.

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.
If the main hydraulic equipment, engine, etc. are retrofitted as an option or replaced, be sure to register the
serial number of the device installed or retrofitted on Global e-Service (MMR, HR, MME, and G-Claim).

ZX-1/3/5/6/GI and ZH-5/6: All serial numbers


ZXW-5/6 and ZW-5/6: All serial numbers
Verify details of the target Serial number on Global e-Service S/B system.

STD. LABOR HOURS


1 hour / one person

EXPENSES AND THE TIME TO BE CHARGED


Charge to the customer.

PARTS
Wire harness (ST8322), wire harness (YA00047892) (In stock)

DESCRIPTION

Refer to the following page(s).

DWN
CHKD
SA/GI: ZX-5 (all)-138, ZX-6 (all)-022 APPD
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Contents ZX-5-All-226,
ZX-6-All-204
(Revised)
Page

1 Preconditions ........................................................................................... 3

2 Workflow ................................................................................................... 4

3 Downloading the controller software ..................................................... 5

4 Importing the downloaded controller software ..................................... 5

5 Checking the controller version.............................................................. 7

6 Troubleshooting ..................................................................................... 10

7 Removing the rear trays in the crawler excavator STD cab or


wheel excavator...................................................................................... 12

8 Removing the rear tray in the crawler excavator US cab ................... 17

9 Rewriting the controller software ......................................................... 20

10 Connecting the rewriting harness for the clawer excavator or


wheel excavator...................................................................................... 27

11 Installing the rear trays onto the crawler excavator STD cab or
wheel excavator...................................................................................... 29

12 Installing the rear tray onto the crawler excavator US cab ................ 33

13 Connecting the rewriting harness for the wheel loader...................... 35

14 Disconnecting the rewriting harness for the wheel loader ................. 38

15 Uploading the rewritten data ................................................................. 41

16 Viewing the controller reprogramming history.................................... 42

17 Note on checking the communication status after rewriting ............. 43


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1 Preconditions ZX-5-All-226,
ZX-6-All-204
1-1 Compatible service tool versions (Revised)
- AllinOneTool Ver…2.17.0.0 or later
- MPDr. (*1) Ver…2.41.0.0 or later (*1) For the Tier-4 areas: Adjustment function edition
For the Tier-3 areas: Adjustment function edition

1-2 Other required software


- Controller rewriting file for communication terminals (HPRO)

1-3 Notes
Obtain the compatible service tools in the same way as before, by upgrading from the AllinOneTool tool list.
The controller rewriting file for mobile line terminals (HPRO) can be obtained from GeS M-PRO SV.
The MaintenancePRO administrator in each office needs to make the file publicly accessible.

1-4 Preparing a harness for rewriting mobile line terminals


Series Connect to Harness part No. Remarks
ZX-1, ZX-3,
ZX-5/6/GI
ZH-5/6 Mobile line terminal (HPRO) ST8322
ZXW-5/6
ZW-5/6
To be used
only for
ZW-5/6 Power cable YA00047892
rewriting for
wheel loaders
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2 Workflow ZX-5-All-226,
ZX-6-All-204
Check the preconditions. See 1. Preconditions.
(Revised)

The AllinOneTool
version is 2.17.0.0 or
later.
Update the AllinOneTool version.

Is the MPDr. version


2.41.0.0 or later?

Update the MPDr. version.

Download the mobile line terminal


software. See 3. Downloading the controller software.

Import the downloaded file. See 4. Importing the downloaded controller software.

The operations from here


on are on the machine.

Check the controller version. See 5. Checking the controller version.

Troubleshooting See 6. Troubleshooting.

Wheel loader Crawler excavator and wheel excavator

See 7. Removing the rear trays in the crawler


Remove the rear trays in the crawler excavator STD cab or wheel excavator or 8.
Connect the rewriting excavator or wheel excavator. Removing the rear tray in the crawler
See 9. Rewriting the excavator US cab.
harness for loaders. Use controller software and 13.
MPDr. to rewrite the Connecting the rewriting
software. Use MPDr. to rewrite the See 9. Rewriting the controller software and
harness for the wheel 10. Connecting the rewriting harness for the
software.
loader. clawer excavator or wheel excavator.

Check the controller version. See 5. Checking the controller version.

See 6. Troubleshooting.
Troubleshooting
Note: When checking the communication status after rewriting, see
the note below.
17. Note on checking the communication status after rewriting
Install the rear tray(s). See 11. Installing the rear trays onto the crawler excavator STD
cab or wheel excavator or 12. Installing the rear tray onto the
crawler excavator US cab.

Set the time. See the Operator’s Manual for the machine model to be
rewritten.
The operations from here on
are at the office.

Upload the rewritten history data. See 13. Uploading the rewritten data.

Check the history data on Global e-


Service. See 14. Viewing controller reprogramming history.
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3 Downloading the controller software ZX-5-All-226,
Open Global e-Service > Service > MaintenancePRO. Download the software ZX-6-All-204
under [Other: File for reprogramming controller]. (Revised)
Note: The software shown below is only an example. Download
the necessary file.

4 Importing the downloaded controller software

4-1 Start AllinOneTool. Click [Import].

4-2 Click [Ref.].


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4-3 Select the downloaded file. Click [Open].
ZX-5-All-226,
Note: The file shown below is only an example. Select the file downloaded from ZX-6-All-204
Global e-Service.
(Revised)

4-4 Click [Import].

4-5 Click [OK].

4-6 Make sure that the text is shown in the Succeeded field.
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5 Checking the controller version ZX-5-All-226,
ZX-6-All-204
5-1 Connect MPDr. to the machine. Turn the key to ON. (Revised)
Note: Connect to the MPDr. connector in the fuse box.
 MPDr. connector location in a clawer excavator and wheel excavator

 MPDr. connector location in a wheel loader


MPDr. connector

5-2 Select the applicable machine model on the model selection screen.
Note: In these procedures, the ZX-6 is selected as an example.

5-3 After selecting the machine model, click [Connect].


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5-3 Click [Functions].
ZX-5-All-226,
ZX-6-All-204
(Revised)

5-4 Enter the password. Click [OK].

5-5 Click [Others].


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5-6 Click [Controller Version].
ZX-5-All-226,
ZX-6-All-204
(Revised)

5-7 Read the version to the right of [Mobile Line Terminal].

This completes the procedure for checking the controller version.


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6 Troubleshooting ZX-5-All-226,
ZX-6-All-204
6-1 Start MPDr. (Revised)

6-2 Select the applicable machine model on the model selection screen.
Note: In these procedures, the ZX-6 is selected as an example.

6-3 After selecting the machine model, click [Connect].

6-4 Click [Troubleshooting].


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6-5 Select [Start] to execute troubleshooting.
ZX-5-All-226,
ZX-6-All-204
(Revised)

6-6 After troubleshooting has finished, make sure that no faults are shown to the right of
[Information Controller].

6-7 If any faults are shown, click [Retry]. Make sure that no faults are shown.

Note: If faults persist even after several retries, refer to the Technical Manual to fix it.
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7 Removing the rear trays in the crawler excavator STD cab ZX-5-All-226,
or wheel excavator ZX-6-All-204
(Revised)
7-1 Make sure that the machine's key switch is set to OFF.

7-2 Remove the rear tray located behind and to the right of the seat.

7-2-1. Remove the two caps.


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7-2-2. Remove the three screws.
ZX-5-All-226,
ZX-6-All-204
(Revised)

7-3 Remove the rear tray located behind and to the left of the seat.
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7-3-1. Remove the fuse cover and then remove the screw and bolt.
ZX-5-All-226,
ZX-6-All-204
(Revised)

7-3-2. Disconnect the cigar socket harness.


Page 15 of 43
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7-4 Remove the rear tray located behind and under the seat.
ZX-5-All-226,
7-4-1. Remove the three caps. ZX-6-All-204
(Revised)

7-4-2. Remove the three screws.

7-4-3. Remove the two bolts.


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7-5 After the specified rear trays are removed
ZX-5-All-226,
Connect the plug and flat terminal to the harness to be connected to the cigar ZX-6-All-204
socket.
(Revised)
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8 Removing the rear tray in the crawler excavator US cab ZX-5-All-226,
ZX-6-All-204
8-1 Make sure that the machine's key switch is set to OFF. (Revised)

8-2 Remove the four caps.

As seen from above

8-3 Remove the four bolts under the removed caps.


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8-4 Remove the cover located behind and to the left of the seat. ZX-5-All-226,
Remove the three bolts. ZX-6-All-204
(Revised)

8-5 Remove the three bolts from the cover in the bottom of the seat.

8-6 Remove the harness under the seat to remove the rear tray.

Remove the connector and clip located behind and to Disconnect the connector located
the right of the seat enclosed in the pink squares. behind and to the left of the seat.
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8-7 Pull out the rear tray upward.
ZX-5-All-226,
ZX-6-All-204
(Revised)

8-8 Disconnect the cigar socket and harness after removing the rear tray. They will be used as
a power source to rewrite the MCZ.

8-9 Connect the removed cigar socket and harness to the original cab harness connector.
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9 Rewriting the controller software ZX-5-All-226,
ZX-6-All-204
9-1 Start MPDr. (Revised)

9-2 Select [Rewrite of the Communication Terminal (HPRO)] on the model selection screen.

9-3 Click [Connect].

9-4 Click [Rewrite of the Communication Terminal (HPRO)].


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9-5 Turn the key to OFF.
ZX-5-All-226,
Disconnect the cable connected to the communication terminal. Connect the ZX-6-All-204
rewriting harness. Click [Next].
Note: For the detailed procedures for connecting the rewriting harness, see 10. (Revised)
Connecting the rewriting harness for the clawer excavator or wheel excavator or 13. Connecting the
rewriting harness for the wheel loader.

9-6 Turn the key to ACC. Click [Yes].

9-7 Click [Execute] to the right of [Communication Test] to execute a communication test.
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9-8 Check that the communication test results are as shown below.
- Communication test result…"OK"
ZX-5-All-226,
- Rewriting file…"Acquired" ZX-6-All-204
After the check, click [Next]. (Revised)

Note: If the error window shown below appears, handle the error appropriately according to its content.
- Check the connection of the harness between the communication terminal and MPDr.

- The controller rewriting file for communication terminals (HPRO) compatible with the connected communication
terminal has not been acquired.
Obtain the controller rewriting file in accordance with 4. Importing the downloaded controller software.

- The software for the connected communication device cannot be detected. Execute forced rewrite in accordance
with the procedures shown below.
Note: When forced rewrite is executed, rewriting history to be uploaded to Global e-Service cannot be
kept.
(1) Click [Yes].

(2) After checking the label on the communication terminal, enter the terminal type and part number and click
[Execute].
22
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Note: When the window shown below is displayed, download the rewriting file
ZX-5-All-226,
from GeS. ZX-6-All-204
Use AllinOneTool to import it. (Revised)
2

(3) Click [Next].


Go to step 9-11.

Carry out the procedures starting step 9-11.

9-9 Click [Execute] to the right of [Data Backup].


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9-10 Click [OK].
ZX-5-All-226,
ZX-6-All-204
(Revised)

9-11 Select the target file from the rewriting file list. Click [Execute].

9-12 Click [Yes].

Rewriting begins. Wait for a while.

9-13 Click [OK].

Note: After the window shown on the


left is displayed, be sure to turn the
key to OFF.
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9-14 Click [Next].
ZX-5-All-226,
ZX-6-All-204
(Revised)

9-15 Click [Execute] to the right of [Communication Terminal: Initialize].

9-16 Click [OK].

9-17 Click [Execute] to the right of [Data Restore].


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9-18 Click [OK].
ZX-5-All-226,
ZX-6-All-204
(Revised)

9-19 Click [Next].

9-20 Turn the key to OFF.


Disconnect the rewriting harness connected to the communication terminal. Connect the normal harness.
Click [Next].
Note: For the detailed procedures for connecting the rewriting harness, see 10. Connecting the rewriting
harness for the clawer excavator or wheel excavator.
See 13. Connecting the rewriting harness for the wheel loader.

This completes the rewriting of the controller software.


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10 Connecting the rewriting harness for the clawer excavator ZX-5-All-226,
or wheel excavator ZX-6-All-204
(Revised)
10-1 Disconnect the machine harness from the controller. Connect the rewriting harness.
 Communication terminal location
- ZX-5, ZX-6 Crawler excavator STD cab - ZX-5, ZX-6 Crawler excavator US cab

- ZXW-5, ZXW-6 Wheel excavator cab - ZX-1 Clawer STD cab

- ZX-3 Clawer STD cab - ZX-3 Clawer US cab


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- Connected rewriting harness (insert it until the tabs click)
ZX-5-All-226,
ZX-6-All-204
(Revised)

Rewriting harness (part No. ST8322)

10-2 Connect the plug and flat terminal of the rewriting harness to
the harness to be connected to the cigar socket.
(On the machine side)
Harness to be connected
to the cigar socket

(On the rewriting


harness side)
Plug and flat terminal

Rewriting harness (part No. ST8322)


10-3 Connect the rewriting harness to the USB serial conversion cable.
Note: If the PC has a serial connector, connect the rewriting harness to the
connector.

Rewriting harness (part No. ST8322)


USB serial conversion cable

10-4 Connect the USB serial conversion cable to the PC.


Note: Connect the MPDr. cable and rewriting harness to the same communication port (serial
connector) of the PC. Otherwise a communication error appears and the software cannot be
rewritten.

PC for rewriting
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11 Installing the rear trays onto the crawler excavator STD ZX-5-All-226,
cab or wheel excavator ZX-6-All-204
(Revised)
11-1 Install the rear tray behind and under the seat.

11-1-1. Install the two bolts.

11-1-2. Install the three screws.

11-1-3. Install the three caps.


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11-2 Install the rear tray behind and to the left of the seat.
ZX-5-All-226,
11-2-1. Make sure that the black connector has been installed. ZX-6-All-204
(Revised)

11-2-2. Make sure that the harness has been connected to the cigar socket.
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11-2-3. Attach the fuse cover. Install the screw and bolt.
ZX-5-All-226,
ZX-6-All-204
(Revised)
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11-3 Install the rear tray behind and to the right of the seat. ZX-5-All-226,
ZX-6-All-204
11-3-1. Install the three screws. 13-3-2. Install the two caps. (Revised)
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12 Installing the rear tray onto the crawler excavator US cab ZX-5-All-226,
ZX-6-All-204
12-1 Install the cigar socket and harness. (Revised)

12-2 Install the rear tray in its original position.

12-3 Connect the harness under the seat.


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12-4 Install the three bolts into the cover on the bottom of the seat.
ZX-5-All-226,
ZX-6-All-204
(Revised)

12-5 Remove the cover behind and to the left of the seat. Install the three bolts.

12-6 Install the four bolts shown below. Then install the caps.

As seen from above


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13 Connecting the rewriting harness for the wheel loader ZX-5-All-226,
ZX-6-All-204
13-1 Connect the rewriting harness to the controller. (Revised)

Part No. YA00047892


GND-2
250 female
terminal
With cap

Toggle switch
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13-2 Disconnect the machine harness from the controller. Connect
the rewriting harness. ZX-5-All-226,
ZX-6-All-204
(1) Disconnect the machine harness. Connect the rewriting harness to the
communication terminal.
(Revised)
(2) Connect the plug and flat terminal of the rewriting harness to the harness to be connected to the cigar
lighter socket.
(3) Connect the rewriting harness to the USB serial conversion cable.
Note: If the PC has a serial connector, connect the rewriting harness to the connector.

(2) Connect the plug and flat terminal of the


rewriting harness to the harness to be
connected to the cigar lighter socket.
Part No. YA00047892
GND-2
250 female terminal
With cap
(On the machine side)
Harness to be connected
to the cigar lighter socket

Toggle switch

(On the rewriting


Part No. ST8322 250 male terminal
Note: Use a shrinkable tube to protect harness side)
the caulked section of the wire.
Plug and flat terminal

Plug (male)

D-SUB 9-pin female


(With hood)

(3) Connect the rewriting harness to the USB (1) Disconnect the machine harness.
serial conversion cable. Connect the rewriting harness to the
Note: If the PC has a serial connector, connect communication terminal (insert it until
the rewriting harness to the connector. the tabs click).
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13-3 Connect the USB serial conversion cable to the PC.
ZX-5-All-226,
Note: Connect the MPDr. cable and rewriting harness to the same ZX-6-All-204
communication port (serial connector) as the PC. Otherwise a
communication error appears and the software cannot be rewritten. (Revised)

PC for rewriting

13-4 Install a fuse.

Insert a 5-A fuse.


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14 Disconnecting the rewriting harness for the wheel loader ZX-5-All-226,
ZX-6-All-204
14-1 Remove the fuse. (Revised)

Remove the 5-A fuse.

14-2 Disconnect the USB serial conversion cable from the PC.

PC for rewriting
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14-3 Disconnect the rewriting harness. Connect the machine harness.
ZX-5-All-226,
(1) Disconnect the rewriting harness. Connect the machine harness to the ZX-6-All-204
communication terminal.
(2) Disconnect the plug and flat terminal of the rewriting harness from the (Revised)
harness to be connected to the cigar socket.
(3) Disconnect the rewriting harness from the USB serial conversion cable.
Note: If the rewriting harness has been connected to the PC's serial connector, disconnect the rewriting
harness from the serial connector.
(2) Disconnect the plug and flat terminal of
the rewriting harness from the harness to be
Part No. YA00047892 connected to the cigar lighter socket.

(On the machine side)


Harness to be connected
to the cigar lighter socket

(On the rewriting


Part No. ST8322
harness side)
Plug and flat terminal

(3) Disconnect the rewriting harness from the USB


serial conversion cable.
Note: If the rewriting harness has been connected
to the PC's serial connector, disconnect the (1) Disconnect the rewriting harness.
rewriting harness from the serial connector. Connect the machine harness to the
communication terminal.
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14-4 Remove the power harness from the machine.
ZX-5-All-226,
ZX-6-All-204
(Revised)

Part No. YA00047892

14-5 Install the body cover.


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15 Uploading the rewritten data ZX-5-All-226,
ZX-6-All-204
15-1 Start MPDr. (Revised)

15-2 Click [Upload] on the model selection screen.

15-3 Click [OK].

15-4 Enter the Global e-Service ID and password. Click the [Upload] button.

This completes the uploading of the rewritten data.


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16 Viewing the controller reprogramming history ZX-5-All-226,
ZX-6-All-204
16-1 Log in to Global e-Service. Select [M-Find (Machine Find)] under (Revised)
[Machine].

16-2 Search for the reprogrammed serial number. Make sure that the reprogramming history is
present.
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17 Note on checking the communication status after rewriting ZX-5-All-226,
Note: When the communication status is checked immediately after rewriting, ZX-6-All-204
"2000/01/01 00:00:00" may be displayed in Time of Previous Transmission (Revised)
and Time of Previous Receiving.
This is because the internal data has been initialized due to the rewriting of the software.
When the number of unsent data pieces is other than zero, the date is updated once the data
transmission completes.
When the number of unsent data pieces is zero, the date is not updated because there is no data to be
sent.
If you wait for a while (two to three minutes) after the rewriting, the number of unsent data pieces
becomes other than zero.

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