Hitachi Vehicle Interface Manual - HTT-32-0109

Hitachi Vehicle Interface
Manual
Publication Number: HTT-32-0109

1/19/2009
THIS PAGE LEFT INTENTIONALLY BLANK
Table of Contents
Introduction ........................................................................................................ 1
Obtaining Software ..................................................................................................................1
ECU Software ..................................................................................................... 5
Applicable Models ...................................................................................................................5
Required Tools.........................................................................................................................5
Software Programs ..................................................................................................................6
HyperTerminal.................................................................................................................6
Contronic/Haultronics III Software...................................................................................6
HyperTerminal Software.................................................................................... 7
Rewriting the ECU Program....................................................................................................7
ECU Programming Setup................................................................................................7
Programming the ECU ....................................................................................................8
Contronic/Haultronics III ................................................................................. 14
Upgrading From Prior Versions of Contronic/Haultronics Software.................................14
Installing Contronic/Haultronics III.......................................................................................14
Contronic/Haultronics III Set Up Procedure ........................................................................20
Contronic/Haultronics III System Calibration......................................................................21
Contronic/Haultronics III Option Selection..........................................................................24
Contronic/Haultronics III Download Instructions................................................................25
CCU Software ................................................................................................... 29
Applicable Models .................................................................................................................29
Required Tools.......................................................................................................................29
Software Programs ................................................................................................................30
Flash Development Toolkit............................................................................................30
HTM Service Tool .........................................................................................................30
WinLoader3 Software....................................................................................................30
FDT Software .................................................................................................... 31
Installing Flash Development Toolkit...................................................................................31
Rewriting the CCU Program..................................................................................................34
CCU Programming Setup .............................................................................................34
Programming the CCU..................................................................................................34
HTM Service Tool ............................................................................................. 38
Obtaining the HTM Service Tool Software...........................................................................38
Installing the HTM Service Tool Software............................................................................39
Configuring HTM Service Tool .............................................................................................41
Communication Settings ...............................................................................................42
Application Settings.......................................................................................................45
Standard Panel.......................................................................................................................46
General Settings ...........................................................................................................47
Read Function...............................................................................................................48
Write Function ...............................................................................................................49
Hoist Calibration............................................................................................................50
Tire/Rim selection .........................................................................................................51
Options..........................................................................................................................52
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Table of Contents
Haultronics .............................................................................................................................56
Haultronics Calibration ..................................................................................................56
Haultronics Settings ......................................................................................................58
Downloading Haultronics Records ................................................................................60
Haultronics Lights..........................................................................................................61
Advanced Panel .....................................................................................................................62
Advanced Panel Overview: ...........................................................................................63
Standard Tab - General.............................................................................................................................. 63
Standard Tab - Engine and Transmission.................................................................................................. 65
Standard Tab – Electric / Gauge ................................................................................................................ 67
Standard Tab – Brake/Steering/Hoist......................................................................................................... 68
Standard Tab – Warning List...................................................................................................................... 69
Input/Output Tab – Digital/Analog Input ..................................................................................................... 70
Input/Output Tab – Digital Outputs (Lamp-Relay-Solenoids)..................................................................... 71
Input/Output Tab – PWM Outputs (Gauge-Solenoid) ................................................................................72
Load Weigh Tab - Haultronics.................................................................................................................... 73
ATC - EDSC Tab ........................................................................................................................................ 74
Help panel...............................................................................................................................75
About Panel............................................................................................................................75
Exit the application ................................................................................................................75
Winloader3........................................................................................................ 76
Installing WinLoader3............................................................................................................76
Installing the USB to CAN adapter driver ............................................................................77
Programming the Hitachi LCD Instrument Panel ................................................................82
Troubleshooting............................................................................................... 85
Contronic/Haultronics III Communication Errors................................................................85
FDT Communication Errors ..................................................................................................85
HTM Service Tool Communication Errors ...........................................................................86
Selecting a COM Port ............................................................................................................87
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Introduction
Introduction
The software programs and control unit software required to perform the procedures in this manual can be
obtained from the Service e-Cabinet on the Hitachi Construction Machinery Global e-Service, accessible through
the Hitachi Construction Machinery global website http://www.hitachi-c-m.com. The Global e-Service is an
extranet application that will require a username and password to access. Access can be requested by contacting
your local e-Service Administrator.
Figure 1: Hitachi Construction Machinery Website (Global e-Service Log In) and e-Cabinet
Obtaining Software
1. The latest versions of Hitachi software are available on the Global e-Service e-Cabinet.
2. After log in to Global e-Service click [e-Cabinet] under the Service heading
1
Obtaining Software (Continued)
3. Click [Search] under the Operation Menu
4. Enter the word “software” in the “Keyword” box and select “Dump Truck HTM” from the Model Group
Dropdown Menu
5. Click [Search]
2
6. A list of truck interface and control unit software will be generated, find the software for your model (e.g.,
EH1100-3) and click the file name to open the download screen.
7. Click [Download] on the Software file.
3
8. Click [Save]
9. Select desired location on your computer and save the file using the part number for the software (e.g.,
12650884P04.mot file, (PXX represents the latest revision of the file, i.e. 01, 02, etc), click [Save] to
begin download.
4
ECU Software
ECU Software
This section provides information on how to install Contronic ECU software using the HyperTerminal software
program and how to use the Contronic/Haultronics III software to calibrate the Contronic/Haultronics III system,
set up parameters, select optional functions, and download haul cycle data.
Applicable Models
The information contained in this section is for the following models of Hitachi Truck:
• EH700
• EH750
• EH1000
• EH1100
• EH1600
• EH1700
• EH3000
• EH3500
• EH4000
• EH4500
• EH4500-2
• EH5000
Required Tools
The following tools and software are required to interface with the Contronic ECU:
• Notebook Computer (Laptop) with:

a) 486 or higher CPU
b) 16MB RAM Memory
c) Windows 95,98, 2000, NT (V4.0 – SP4 or higher), or XP
d) Serial Port COM 1 or COM 2 available
e) RS232 DB9 Connector (or)
f) Universal Serial Bus port (USB to Serial Converter will be required)
• Cable for reprogramming ECU (Hitachi Part Number: E12615274)
• Contronic Service Tool (Hitachi part Number: E12977822)
• HyperTerminal Software
The following additional tools are required to interface with the Haultronics III system:
• Cable Assembly for downloading from ECU (Hitachi Part Number: E12636299 or E12649246,
E12636300, E12636310)
• Contronic/Haultronics III Software
5
Software Programs
There are two software programs you will need installed on your laptop to interface with the Contronic ECU:
1. HyperTerminal Software
2. Contronic/Haultronics III
HyperTerminal
HyperTerminal (also known as HyperTerm) is a communications and terminal emulation program that comes with
the Windows operating system, beginning with Windows 98.
HyperTerminal is used to set up a connection for data transfer between two computers (e.g., your laptop and the
Contronic ECU) using the COM ports.
Contronic/Haultronics III Software

The Contronic/Haultronics III Software is used to perform several functions – dealing with troubleshooting and
calibrating your truck systems. It is also used to obtain Haultronics III Load Weigh system downloads and
Contronic reports useful for preventive maintenance and data trending. The Contronic/Haultronics III Software
used for construction trucks (EH700, EH750, EH1000, EH1100, EH1600, and EH1700) and the one used for
mining trucks (EH3000, EH3500, EH4000, EH4500, EH4500-2, and EH5000) have different part numbers.
Ensure you are using the proper software for the model of truck you are working on.
• Construction Truck Contronic/Haultronics III Software Part Number: E12656685PXX
• Mining Truck Contronic/Haultronics III Software Part Number: E12647671PXX
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Contronic/Haultronics III
HyperTerminal Software
HyperTerminal software is required to upload the ECU software (.bin file) into the Contronic ECU. HyperTerminal
software is already installed on many computers. It can usually be found in the Windows Start Menu under: All
Programs\Accessories\Communications\HyperTerminal.
Rewriting the ECU Program
ECU Programming Setup

1. Open the rear electrical cover in the cab to access the Contronic ECU
2. On the Contronic ECU open the access cover over the rotary switches
3. Place the “Flash Switch” into the programming position (Towards the rear of the hauler)
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ECU Programming Set-up (Continued)
4. Connect the ECU programming cable between ECU connector CN138A and the laptop
5. Start-up laptop
Programming the ECU

1. Start the HyperTerminal program (e.g., double-click 9050.ht):
NOTE: If a window asking if you would like to make HyperTerminal your default internet program
appears, click [NO]
2. The HyperTerminal Window will appear titled with the program name (e.g., 9050 – HyperTerminal)
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Programming the ECU (Continued)
3. Turn the Ignition Switch ON (Do Not Start the Engine), then monitor the laptop screen
4. In the HyperTerminal Window, the screen prompt, (L>), should be in the top left-hand corner, it may be
necessary to scroll up or down to find it
NOTE: If the “L>” prompt doesn’t appear, there is a communication problem:
• Check the cable connection

• If the connection is okay, possibly the cable is connected to a port other than Com1,
(Default setting for the HyperTerminal software)
• Reset Com-port settings for the cable to Com1
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5. At the “L>” prompt, type “load” (Not case sensitive) and press [Enter]
6. The program will ask if you would like to erase the currently stored application program in the ECU, type
“Y”
7. It takes only a few seconds to erase the existing program and then the computer will prompt you that it is
finished and ready to load the 128Kbytes binary file
8. From the main menu at the top of the window, click-on [Transfers]–[Send File]
NOTE: DO NOT select [Send Text File]
9. In the Send File Window enter the name of the file you wish to install in the ECU, (e.g., 12642724.bin)
10
10. If you do not know the filename you can click [Browse] to find it
NOTE: If you can’t find the file when browsing, ensure that “All Files [*.*]” is selected under “Files of
Type:”
11. Once you have found the file click [Send]
12. A file send window will appear showing the file transfer progress
11
13. After the file transfer the program will perform a “checksum”, (this will take 15 to 20 seconds)
14. When the “L>” prompt re-appears, the programming is done
NOTE: Before shutting-down the HyperTerminal program, verify the Contronic ECU software
15. Turn the Ignition Switch OFF
16. Move the “Flash Switch” on the ECU into the RUN position, (Towards the front of the Hauler)
17. Turn the Ignition Switch back ON and the HyperTerminal program will show the version of the software
and if the PROM is okay.
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18. If everything is okay, shutdown the HyperTerminal program, turn the Ignition Switch OFF and disconnect
the programming cable from the CN138A connector.
NOTE: Be sure to reconnect the LED display connection back into the CN138A connector if the Hauler is
equipped with the Haultronics LED display option.
13
The Contronic/Haultronics III Software is used to perform several functions dealing with troubleshooting and
calibrating your truck systems. It is also used to obtain Haultronics III Load Weigh system downloads and
Contronic reports useful for preventive maintenance and data trending.
Upgrading From Prior Versions of Contronic/Haultronics Software

If you are upgrading from an earlier version of Contronic/Haultronics these instructions must be followed prior to
installing the new version of Contronic/Haultronics III Software.
1. All files in the current Haultronics\Data folder must be either deleted or moved to a different folder. The
new Contronic/Haultronics program will not recognize downloaded files from prior versions of the
software.
2. The Contronic/Haultronics Software program currently installed must be removed:
• From the Windows Start menu select [Control Panel]-[Add/Remove Programs]

• Choose either Haultronics for older versions of the software or Contronic – Haultronics Tool for more
recent versions of the software from the list of programs shown, and click [Remove]
• The uninstaller may ask for confirmation before removing some shared files, click [Yes to All]
• Proceed with installation of the new program
Installing Contronic/Haultronics III

1. After copying the Contronic/Haultronics III software program in .zip file format to your computer desktop,
extract the files by double-clicking on the .zip folder then choosing [Extract Files]:
14
Installing Contronic/Haultronics III (Continued)
2. The Extraction Wizard Window will open, click [Next]
3. The Select Destination Window will open, click [Next] to extract files to default location or click [Browse]
to change the file extraction location prior to clicking [Next] to proceed
4. The Extraction Complete Window will open, select [Show extracted files] checkbox and click [Finish]
15
5. The extracted file window will open, double-click [setup.exe] to begin software installation
6. An Open File – Security Warning Window will open, click [Run]
7. The Contronic-Haultronics Tool III Setup Window will open, click [OK]
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8. Click the install button to begin software installation
9. The Choose Program Group Window will open, ensure Contronic-Haultronics Tool is selected and click
[Continue]
10. If you receive any Version Conflict Warnings during software installation click [Yes] to retain your current
(newer) versions of the files being copied
17
11. When the message indicating software installation is completed is received click [OK]
12. The software installation is now complete, the following steps provide instructions on how to make useful
desktop shortcuts for Contronic/Haultronics III
13. Locate and open the Contronic-HaultronicsIII file folder found in the main drive on the computer (typically
drive letter “C”)
NOTE: The folder will have the title Contronic-HaultronicsIII_Mining or Construction depending on what
model of truck the software was designed to work with.
14. To create a desktop shortcut for Contronic-Haultronics III, right-click on the [Contronic-Haultronics Tool
III.exe] icon and select [Copy]
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15. Right-click anywhere on the Windows Desktop and select [Paste Shortcut], a Contronic-Haultronics Tool
III Shortcut will be created
16. To create a shortcut to the Contronic-Haultronics III data folder where all the download reports will be
saved, right-click on the data folder and select [Copy]
NOTE: The Contronic-Haultronics III Software program will need to run at least once prior to the data
folder being created in the Contronic-Haultronics III Folder. The Contronic-Haultronics III Software can be
run without a connection to a Contronic ECU.
17. Right-click anywhere on the Windows Desktop and select [Paste Shortcut], a Shortcut to the data folder
will be created.
NOTE: The shortcut will simply be called “data’, but you can rename this shortcut (e.g., Haultronics III
Data) without losing the shortcut function.
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Contronic/Haultronics III Set Up Procedure
This procedure needs to be done prior to calibrating the Haultronics III system.
1. Ensure the ECU switch settings are correct for the truck model and equipped options, see chart below:
20
Contronic/Haultronics III Set Up Procedure (Continued)
2. Drive the truck for some distance and then stop slowly, parking the truck on a flat level surface
3. Release the park, service and load/dump brakes
4. Turn the steering wheel lock-to-lock several times to release stress on the front strut, then center the
wheels and steering wheel
5. Check the “Struts” Screen on the dash mounted Contronic LCD display to verify the inclinometer reading
6. Adjust the base mounting nuts on inclinometer until the displayed readings for grade are 0.0% ± 0.5%.
NOTE: The inclinometer is located in the electrical compartment behind the buddy seat or inside the
buddy seat depending on truck model
7. Park the truck in the same position facing the opposite direction and repeat steps 2 & 3
8. Check the inclinometer readings again, if the readings are out of the 0.0% ± 0.5% range, find another flat
level surface to perform the adjustment or set the inclinometer with symmetry readings when parked in
the same place facing the opposite direction (e.g., if the inclinometer readings facing the first direction
were set to X = -0.2% Y = +0.3%, readings facing the other direction should be set X = +0.2% Y = -0.3%)
9. Check the top row of any screen on the Contronic LCD to ensure there are no flashing error (ER)
messages, correct any Loadweigh System related errors before proceeding
Contronic/Haultronics III System Calibration
1. Connect the laptop to the ECU data link port using the download harness.
2. Turn the Ignition Switch ON (Do not start the engine)
3. Start the Contronic/Haultronics III Software program, it will look for a connection to the ECU and give a
communication error message if a connection is not detected
4. From the main menu select [Tools]-[Truck Calibration], the Truck Calibration Page will open
5. On the Truck Calibration Page click [Read] to check the existing truck parameter settings
21
Contronic/Haultronics III System Calibration (Continued)
6. If the Model setting is not right refer to the ECU switch setting chart in the “Haultronics III Set Up
Procedure” section of this manual to find the correct ECU switch settings, verify the settings on the ECU
7. Input a 4 digit Truck ID and click [Set] to save it in the ECU
8. Select the options under Payload Options when finished entering the parameters for the options listed
below click [Set] top accept the new Payload Options
• Maneuvering Distance: is the distance to drive away from the loading zone before the final
payload calculation begins. Usually set for 160 meters in order to get out of the loading area
where the ground may be rough or bumpy before processing final calculation. Processing the
final calculation on a rough or bumpy road reduces accuracy. Select one of the possible choices:
40, 80, 120, or 160 meters.
• Final calculation time: is the number of seconds for the processor to calculate final payload. 60
seconds usually gives highest accuracy for final payload. Possible choices are 30, 40, 50 or 60
seconds.
NOTE: For sites with short distance from loading to dump site it may be required to lower the distance
and time, otherwise, final payload may not finish calculation and payload recorded will be static, not final
payload.
• Overload speed restriction: activates for payload over 120%. The restriction can be enabled or
disabled.
9. Under Net Weight, input the clean empty truck weight in the Enter New field and click [Set] to save it in
the ECU
10. Select front and rear tire and rim types from Front Tire, Rear Tire and Front Rim, Rear Rim dropdown
lists. Click [Set] for Tire Weight and Rim Weight items to save to ECU (if the equipped tire and/or rim
type is not on the list, select one with similar specifications)
22
Contronic/Haultronics III System Calibration (Continued)
11. Click [Calibrate] to complete the calibration
12. Click [Save] to save the set up information in a separate file. Print out the file and keep the hardcopy in
the truck record document folder for future warranty purposes.
13. Click [Quit] to finish the truck calibration.
NOTE: Calibration should be executed when the truck is first introduced into production or has a major
modification (e.g., a new attachment or option added).
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Contronic/Haultronics III Option Selection
1. Connect the laptop to the ECU data link port using the download harness
2. Turn the Ignition Switch ON (Do not start the engine)
3. Start the Contronic/Haultronics III Software program, it will look for a connection to the ECU and give a
communication error message if a connection is not detected
4. From the main menu select [View]-[Truck Options], the Truck Options Page will open
5. Click the [Read] button to display current truck option settings:

• Fuel Limit Warning: enter the desired percentage for warning or use the current setting
• Body Up with Speed: enter the warning in km/h or use the current setting
• Seat Belt: check [enable] if Semi Active Seat Kit E12652709P03 is installed in the truck and
warning function is desired; otherwise check [disable]
6. Click [Update] to save the option settings for the truck. Click the [Read] button to verify current truck
option setting changes by loading saved information from ECU
7. Click [X] in the upper right corner of window to finish the truck option selection
24
Contronic/Haultronics III Download Instructions
If this is a new system or you want to clear the Load #, select [Set New System]. This will clear out all load data
and reset load counts. You will be prompted for a password as this function is available to HTM personnel only.
NOTE: After setting new system, check calibration file again to ensure no calibration parameters
changed. If any parameter changed, it will be necessary to re-calibrate the Haultronics III system.
1. With the download harness connected and the engine OFF (Ignition Switch ON), select [Start]-
[Programs]-[Contronic/Haultronics Tool III]. When the program starts, it will look for a connection to
the ECU, and give a communication error message if one is not found. The message may be ignored
when using Contronic/Haultronics Tool III to work off-line with previously downloaded reports.
NOTE: It is no longer necessary to disconnect the data link connectors to the engine and/or transmission
ECMs.
2. Before beginning the download, select the desired “Units” and “Date” format using the [Units] and [Date]
pull down menus. Units may be set to either SI (m-tom/kg/m) or US (s-ton/lb/ft) and the date may be
mm/dd/yy, dd/mm/yy, or yy/mm/dd. The resulting file will be in the format selected.
NOTE: Data will be in the format selected regardless of the date setting selected under Windows,
Regional Options.
3. Select [Download Data] or [Download Bc On]. All loads since the last Delete Old Data operation up
until now will be sent. The result will be in report format, using the units checked in the [Units] pull down
menu.
NOTE: Download Data will shut down the engine link for a faster download (Cummins Engines only) and
should only be done with the engine shutdown. Download Bc On will not shut down any data links so that
the engine may keep running during the download.
25
Contronic/Haultronics III Download Instructions (Continued)
4. It is also possible to download raw data from the Contronic/Haultronics III system using the [Download
Raw] button or selecting [Download Raw] under the [Tools]-[Haultronic Data] or [Contronic Data]-
[Download Raw] drop down menus. The Raw file format will not be readable until converted to a report
by selecting [Tools]-[Haultronic Data] or [Contronic Data]-[Convert Raw to Report] from the drop
down menu.
NOTE: Raw data downloads are typically for HTM diagnostic use only.
5. After deciding what data to download, in what format and selecting the desired function a file save
window will open. Type in a filename (e.g., truck ID and serial number) and press [Save]. The program
will automatically add the “.txt” file extension.
6. Once the download begins, the Download Status Window will appear. A normal download by selecting
[Download Data] will take up to 2½ minutes while a download by selecting [Download Bc On] will take
up to 4½ minutes for the maximum number of loads stored.
26
7. Once the download is complete, verify the data has been received by viewing the file. The Contronic and
Haultronics Files section lists all downloads presently saved on disk. All files may be viewed, printed, or
deleted. You are able to switch between viewing Haultronic download files and Contronic download files
by selecting [View]-[Haultronic Files] or [Contronic Files] from the main menu.
8. Highlight the filename to select it and then choose the desired operation from the toolbar buttons or the
pull down menus. An example file is shown below:
9. The units displayed may be changed by selecting either [US Units] or [SI Units] after the file has been
downloaded. If the Units and/or Date format are changed while viewing a file, the new format will be
saved when the file is closed.
NOTE: The “Digit grouping symbol” defined in the Windows OS under [Control Panel]-[Regional and
Language Options] must be set to a comma (e.g., 154,000). If improperly set (i.e., as a period or
space), conversions from metric to U.S. and vice versa will not be correct.
27
10. Once the file has been saved and viewed, select [Delete Old Data], this clears the downloaded
Haultronics data.
NOTE: After this operation, the truck must run through a complete haul cycle to get more load data.
11. After the data has been deleted, turn the ignition key OFF, and disconnect the cable. You can continue to
use the Contronic/Halutronics III software program to view files off-line.
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CCU Software
CCU Software
This section provides information on how to install and use the Flash Development Tool Kit and the HTM Service
Tool interface software for trucks equipped with the Hitachi CCU and how to install and use the WinLoader3
program used for programming the LCD instrument panel on dash 3 construction trucks equipped with the LCD
instrument panel.
Applicable Models
The information contained in this manual is for the following models of Hitachi Truck:
• EH750-3
• EH1100-3
• EH1700-3
• EH5000ACII
Required Tools
The following tools and software are required to interface with the Hitachi CCU:
• PC-type portable computer with Windows 2000 or XP operating system and at least one available
serial COM port, RS232 DB9 Connector or Universal Serial Bus port (USB to Serial Converter will
be required)
• Hitachi CCU Software (.mot type file)
• Flash Development Tool Kit software
• WinZip Application, Version 10.0 or higher
• Hitachi Service Tool software
• Straight through DB9 Male to DB9 Female - RS232 Cable (3 to 4 feet long)
• USB or PCMCIA to RS232 adapter if your laptop does not have an RS232 port onboard.
• CCU Programming Key
Figure 2: (Left to Right) RS232 DB9 Cable, USB to Serial Adapter, CCU Programming Key
29
The Following tools and software are required to interface with the Hitachi LCD Dash Panel:
• PC-type portable computer with Windows 2000 or XP operating system and at least one available
serial COM port (USB or DB9 type connector)
• Hitachi LCD instrument panel software (s19 type file)
• WinLoader3 programming software
• USB to DB9 CAN adapter
• USB to CAN adapter driver software
• CD – Peak System (Drivers)
• DB9 to J1939 cable
NOTE: All cables and adapters shown above for both the CCU and LCD Instrument Panel are
available as a Software Tool kit from HTM Parts (part number E12650910PXX)
Software Programs
There are two software programs you will need installed on your laptop to interface with the CCU:
3. Flash Development Toolkit (FDT)

4. HTM Service Tool
There is one software program required to update the LCD Instrument Panel software:
1. WinLoader3
Flash Development Toolkit

The FDT is used to upload software to the CCU. This software is contained in files that are called “MOT” files for
short, because of their .mot file extension.
The FDT, under no circumstance, should be loaded directly. Instead the user should double click the appropriate
MOT file and have the FDT auto-load with all of the appropriate configuration details contained in that MOT file.
HTM Service Tool

The HTM Service Tool is used to perform several functions – dealing with troubleshooting and calibrating your
truck systems. It is also used to obtain truck reports useful for preventive maintenance and data trending. The
Service Tool used for construction trucks (EH750-3, EH1100-3, and EH1700-3) and the one used for mining
trucks (EH4500ACII, EH5000ACII) have different part numbers. Ensure you are using the proper software for the
model of truck you are working on.
• Construction Truck Service Tool Part Number: E12659907PXX
• Mining Truck Service Tool Part Number: E1265493PXX
WinLoader3 Software
The WinLoader3 software is used to upload software to the LCD Instrument Panel on construction trucks
(EH750-3, EH1100-3, and EH1700-3). This software is contained in files that are called “S19” files for short,
because of their .s19 file extension.
Example S19 software file name: 60-UD-82180-107-BTL
30
FDT Software
FDT Software
Installing Flash Development Toolkit

The Flash Development Toolkit (FDT) is required to upload the CCU software (.mot file) into the CCU. The
software can be downloaded from the Service e-Cabinet on Global e-Service. If the Flash Development Toolkit is
already installed on the computer being used for vehicle interface you can skip this section.
To install the Flash Development Toolkit proceed with the following steps:
12. Double click FDT15.exe. Click the [Next] button
13. Click the [Yes] button.
14. Click the [Next] button.
31
Installing Flash Development Toolkit (Continued)
32
Installing Flash Development Toolkit (Continued)
20. Select SH/7055F. Click the [Next] button.
21. Click the [Finish] button to complete the installation
33
Rewriting the CCU Program
CCU Programming Setup

1. Connect the RS232 DB-9 download cable to the CCU serial port as shown in the picture below and the
other end in to the PC serial port.
2. Insert the Programming Key in the location indicated in the picture below and turn it to position 1.
3. Turn ON the 24V power supply (the main battery switch and the vehicle Ignition Switch).
4. After power up verify if the built in CCU LED is flashing.
5. If the LED is not flashing, the CCU is in rewrite mode and ready to receive the new program.
6. If the LED is flashing, the CCU is not in rewrite mode. Turn off the power, check for possible errors made
in the previous steps or for bad connections and then try again.
Programming the CCU

1. Start the Flash Development Toolkit by double-clicking on the MOT file. The Flash Development Toolkit
Window will open:
NOTE: Under no circumstance, should FDT be launched directly from either the Windows Start Menu or
by double-clicking the FDT icon. Instead the user should double-click the appropriate MOT file and have
the FDT auto-load with all of the appropriate configuration details contained in the MOT file.
34
Programming the CCU (Continued)
2. From the main menu select [File]-[Open] and select CCU program from the location where you had
downloaded the MOT file and the MOT File Window will open.
3. From the Menu select [Image]-[Download Image] and the following window will open:
4. Select the communication settings as indicated in the following:
Device Selection:
• Target Device: SH/7055F
User Settings:
• Use Default Settings: Unchecked if COM Port and Baud rate are different that indicated below.
• COM Port: Identify the port you are using for serial communication
• Baud Rate: 19200
Connection:
• Boot Mode: selected
• Select Interface: Direct Connection
• Kernel Already Resident: unchecked
5. Click the [Connect] button and the PC will start the communication with the CCU.
6. If the following error message appears, turn the Ignition Switch OFF, the turn it back again; wait for
minimum 2 seconds then click [Yes] or start over from step 4.
35
7. If the PC is communicating with CCU, the button “Download File (file name).mot to device” becomes
available.
8. Click [Download file “filename.mot” to device]. The rewrite process is started as shown in the figure
below:
9. When the rewrite is finished, a message appears asking to verify or not the downloaded data. Click [Yes]
to verify the downloaded data.
NOTE: If there are errors, the program will stop and need to start over from step 1.
36
10. If the verification process is successful the message log should confirm the programming success as
shown in the picture below:
Verification
Message
11. After the verification is successful complete the programming process as follows:
• Turn Ignition Switch OFF

• Turn the Programming Key Switch to position 0 and remove it
• Turn Ignition Switch ON
• The built in CCU LED should flash every second
• Verify if the software part number and release date corresponds to the version you just downloaded
• Turn Ignition Switch OFF, Hitachi CCU programming is finished
37
HTM Service Tool
HTM Service Tool
Obtaining the HTM Service Tool Software

The latest version of the “HTM Service Tool” is available on the Hitachi Global e-Service website in the same
location as the software for each model of truck as outlined in the “Obtaining Software” instructions in a previous
section of this manual.
CCU Software
Hitachi Service Tool Software
Once the .Zip file has been downloaded from the Global e-Service website:
1. Unzip the downloaded file into a known directory, following the unzip wizard.
2. Verify if the resulting unzipped files are as shown in picture below:
3. Check with your dealer or with HTM Technical Support Department for the latest software information.
38
Installing the HTM Service Tool Software
If a previous version of the HTM Controller/Service Tool software is already installed on the computer it will need
to be removed prior to installing the current version of HTM Service Tool Software:
• From the Windows Start menu select [Control Panel]-[Add/Remove Programs]

• Choose HTM Service Tool from the list of programs shown, and click [Remove]
• The uninstaller may ask for confirmation before removing some shared files, click [Yes to All]
• Proceed with installation of the new program
To install the “HTM Service Tool Software” double click the setup.exe file found in the directory where the “HTM
Service Tool” was unzipped and follow the installation wizard as described in the following:
2. Select the access for the software by choosing “Everyone” or “Just me” then click the [Next] button.
• If “Everyone” is selected all users on the target computer will have access to the application
• If “Just me” is selected only the current user will have access to the application
NOTE: If installing the software on a shared laptop ensure “Everyone” is selected.
39
Installing the HTM Service Tool Software (Continued)
3. Click the [Next] button
4. Wait for software to install, then once completed click the [Done] button.
5. Once the installation process is complete the application files will appear in the installation directory in the
as shown below:
40
Configuring HTM Service Tool
To start the Service Tool Software click the Windows [Start] button then select [All Programs]-[HTM Service
Tool] or double click the shortcut found on your computer desktop. The HTM Service Tool Window will open:
Figure 3: HTM Service Tool Log-in Screen
There are three “User Modes” available:
Customer
• No password required, provides read only features.
Dealer/Manufacturer
• Requires a password from HTM Technical Support or your local dealer and is only available to approved
users. This mode provides read/write access rights to vehicle settings.
Engineering
• Requires a password and is reserved for engineering use.
41
Configuring the HTM Service Tool (Continued)
Pictured below is the main window of the application. The user mode is displayed right above the main menu. All
the entries in the application are done through the Main menu or known short cut keys (e.g., F7 to open Standard
Panel).
User Mode
Figure 4: HTM Service Tool Main Screen
Communication Settings
1. From the Main menu select [Tools]-[Communication], as shown in the figure below:
42
Communication Settings (Continued)
2. The Communication Window will open:
3. Select the COM port connected to the CCU.
NOTE: For best communication all the other settings should remain as shown in the figure above.
Observations:
• The [Default] button restores the settings to match the CCU communication settings.
• The COM port is related to the physical connection and has to be selected according to the cable
connection as defined by the user’s PC.
• The [Test] button verifies the communication.
4. Once settings are complete click the [Test] button.
• If the com port doesn’t exist a message saying that “Port COM(# )is not available” will open:
• If the settings (COM port, Baud Rate, etc) or the connections to the CCU are incorrect the following
message will open:
43
Communication Settings (Continued)
• If all the settings and connections are correct a text message at the bottom of the panel will indicate
“Communication Test Successful”.
5. Click the [Exit] button found on the Communication Window to save the settings.
6. To cancel all the changes or exit the Communication Window without saving the changes, click the
[Cancel] button.
NOTE: The communication settings are retrieved from the database when the application is started.
44
Application Settings
1. From the Main menu select [Tools]-[Application Settings], as shown in the figure below:
2. The Application Settings Window will open:
3. The Application Settings Window enables the selection of language and units of measure.
Units of Measure
• Choices for units of measure are shown in the table below:
Units Temperature Speed Distance Pressure Weight

SI (Système International) Celsius Km/h Km MPa m-ton
MKS (Meter Kilogram Seconds) Celsius Km/h Km Bar m-ton
Imperial Fahrenheit Mph Mile Psi s-ton
Language
• This revision of the application has only one language choice, English. Other language options will
be added in later revisions of the software.
45
Standard Panel
The Standard Panel is reading and writing general settings to the Hitachi controller. The general settings are a
set of parameters that are stored permanently in the controller.
These parameters are grouped by functional categories.
To open the Standard Panel Window from the Main menu select [Contronic]-[Standard Panel], as shown in the
figure below:
The Standard Panel Window will open:
Tab Control
Read/Write
Buttons
Status Bar
Initial Standard Panel status:
• All fields are empty and disabled

• The Status Bar indicates “No Readings!” and the current choice for the units of measure
• The [Write] button is disabled
46
General Settings
Information Groups - Description:
1. Identity
• Model – The vehicle model (selectable from a list)

• Eng Model – The engineering model, associated with the model (read only)
• Make – The vehicle make (read only)
• Serial Number – The vehicle serial number (editable)
• Vehicle ID – Custom identifier four customer tracking purposes (editable)
• Unit Number – Reserved field (not in use)
2. Tire/Rim type
• Tire front/rear – Front and rear tire type (read only in this page)
• Rim front/rear – Front and rear rim type (read only in this page)
3. Overall Rear Axel Ratio
• Defines the rear axle ratio (selectable from list)
4. Operation
• Travel distance - Total vehicle traveled distance (editable)

• Engine hours - Number of hours while the engine was running (editable)
• Vehicle hours - Hours while the vehicle speed was greater than 0 (editable)
• Vehicle Idle hours - Hours while the vehicle speed was zero (editable)
5. Weight
• Max GMW – Represents the gross machine weight (read only)

• Net weight – Represents the net weight (editable)
• Maximum payload – Represents the maximum allowed payload (read only)
• GMW = Net weight + Maximum payload
6. CCU Software
• Part Number – Represents the software part number (read only)

• Release Date – Represents the date when the software was released (read only)
7. Date and Time
• CCU Time Zone – Represents the time zone stored in the CCU (selectable from list)
• CCU Local Date/Time – Represents the date and time stored in the CCU (read only)
8. Hoist Calibration
• Body angle – Represents the current calculated body angle (read only)
• Cal Coef – The calibration coefficient applied as offset to the body angle sensor reading (editable)
• Body Stop – Represents the maximum body angle limit (editable)
47
Read Function
Click the [Read] button to read data from the CCU. If there are no communication errors, the Standard Panel will
be populated with the read information. An example of successful read operation is given in the picture below:
If the read operation was successful all the [Edit] checkboxes are enabled.
NOTE: Select the related [Edit] checkbox to edit data. Fields depending on selection stay disabled (i.e.
Engineering Model depending on Vehicle Model). See white/gray field background.
Status bar messages:
Action Result Status Bar Message

Standard Panel just opened Success No Readings!
Read/Write Success Last Read/Write hh:mm:ss [xx.xx]sec
Read/Write Error Error reading/writing “Data Type” data
Select Model Success Default Data Base Values for EHXXXXX-X
Hoist Calibration Success Write – Hoist Cal dd-mm-yyyy hh:mm:ss Duration xx.xx sec
Hoist Calibration Error Error – Hoist Cal dd-mm-yyyy hh:mm:ss Duration xx.xx sec
48
Write Function
In order to perform a write operation the following information is required:
Model Local Time Zone

Engineering model* Overall Rear Axle Ratio
Make* Maximum GMW*
Serial number Net Weight**
Tire type Payload Limit*
Rim Type
*These parameters will be automatically selected based on the choice of other fields (e.g., Engineering Model
determined by the Model field)
**Initially the “Net Weight” is defaulted to the calculated database value.
NOTE: If the Haultronics system is enabled and calibrated, changing the net weight value will alter the
Haultronics calibration.
Special Validation
There are two data groups that need a [Write] checkbox to be selected and require special validation to write:
1. Operation
2. Date and Time check
To start the write operation, click the [Write] button. One of the following messages will open:
If special validated items are chosen or options are enabled the confirmation message box will show these items:
49
The status bar confirms the write operation result as described in the following table:
Action Status Status Bar Messages

Write Success Write dd-mm-yyyy hh:mm:ss Duration xx.xx sec
Write Error Error reading/writing “Data Type” data
In case of error during the write operation the following message will open:
NOTE: This message communicates what information failed when writing (e.g., Standard Parameters or
System Parameters …). This information is useful for troubleshooting.
Hoist Calibration
The Hoist Calibration section is found on the General Settings Page.
The [Read Live] button enables the user to adjust or to visualize the body angle. The [Calibrate] button performs
the hoist calibration.
Hoist Calibration Procedure:
1. Ensure the body is fully lowered and sitting on the frame rails.
2. Click the [Edit] checkbox.
3. Type 0 in the “Cal Coef” textbox.
4. Type 100 (or desired body stop angle, range 70% to 100%) in the “Body Stop” text box.
NOTE: The proper Body Stop Angle should be determined by measuring the hoist cylinder’s final stage
of extension. The Body Stop Angle should be set to within 100mm (~4in) of full extension measured on
the final stage, i.e., if final stage of cylinder = 1016 mm (40 in) set so body stops when final stage
measures 916 mm (~36in).
5. Click the [Calibrate] button and confirm calibration (ignore turn off message this time).
6. Click the [Read Live] button to monitor the body angle.
7. If the read body angle is not between -10% and 10% adjust the body angle sensor until reading a value
between -10% and 10%, and then secure the adjustment.
50
Hoist Calibration (Continued)
8. Type the body angle in the “Cal Coef” box (if negative type in negative) then push the [Calibrate] button
to calibrate.
9. Click the [Read Live] button to read the body angle.
10. If the body angle is 0 and the “Cal Coef” has the value just typed in, than the hoist is properly calibrated.
If not repeat the procedure carefully.
11. Turn Ignition Switch OFF and wait for 15 sec to save the calibration.
NOTE: Hoist calibration is not performed by using the [Write] button.
Tire/Rim selection
Information Description
• Type – represents the manufacturer type description (selectable from list)

• Part Number – Hitachi part number (read only)
• Manufacturer – name of the manufacturer (read only)
• Weight – tire/rim weight (read only)
Click the [Edit Tire/Rim] button for the Rims/Tires Window to open:
Using this window select the rim and tire type that the vehicle is equipped with. The rim and tire dropdown lists
are populated according to the vehicle model.
51
Tire List/Spec’s
Click the [Tire List/Spec’s] button and the Tire Specification Window will open.
The Tire Specification Window enables the user to browse through the available tire specifications for the
selected truck model. The information in this window is useful in case the tire mounted on the truck is not found in
the tire list and you need to choose an equivalent tire size in order to perform the software settings.
Options
Click the [Options] tab to get to the Options Page, see picture below:
This page is used to enable and set the vehicle options. Some options may require the presence of dedicated
hardware in order to function. Click the [Edit] checkbox in order to have access to the controls.
52
NOTE: When enabling any option you need to perform option settings. Failing to perform option settings
could cause improper or unexpected behavior of the selected option.
The [Reset All Options] button allows the technician to reset all options at once.
Sound Suppression
Click the [Detail] button and the Details Window will open:
This read only window is displaying the maximum allowed engine speed for various gears when sound
suppression is enabled. The displayed engine speed limitations are in effect only if sound suppression is enabled.
Hill Hold
Click the Hill Hold [Settings] button and the Hill Hold Settings Window will open
This window allows the hill hold trigger delay to be set.
Hill Hold Time Delay represents the elapsed time before hill hold will engage if hill hold conditions are satisfied.
The time delay is counted from the moment any brake pedal is pressed if both brake pedals were initially
released.
• Minimum delay: 1 sec

• Maximum delay: 10 sec
53
Haultronics
This option is explained in its own section later in this manual.
Water Truck
Click the Water Truck [Settings] button and the Water Truck Settings Window will open:
With this option enabled only the body up valve is functional in order to engage or disengage the main water truck
pump. When the hoist levers is in the raised or hold position the body up valve is open. For the hoist lever in body
down or float the body up valve is closed.
The “valve pulse width” setting determines if the body up valve is fully or partially open (100% pulse width
corresponds to fully open). This setting allows, if necessary, to regulate the speed of the main water pump.
Engine Idle Timer
Click the Engine Idle Timer [Settings] button and the Engine Stop Delay Settings Window will open:
This option requires the engine idle timer switch to be installed in the dash board. If this option is enabled and the
engine idle timer switch is ON, the engine will continue to run for the amount of time selected in this option after
the Ignition Switch is turned OFF.
The engine can be stopped before the delay time is consumed if the Engine Idle Timer Switch is turned OFF or if
the Emergency Stop Button is pushed. If the Ignition Switch is turned back ON before the engine has stopped the
engine will continue to run until the Ignition Switch is turned OFF again.
54
Report
Click the [Read] button then on the [Report] tab to get to the Report Page.
The Report Page displays CCU settings and allows the user to save this information to a text file.
NOTE: The Report Page is empty if no reading operation was performed. Each reading will refresh the
Report Page with the latest read information.
To save the report to a file, click the [Save Report] button and the Save Report Window will open:
The path is defaulted to “C:\HTMControllerTool\Reports” and the file name is defaulted to the truck serial number.
Both the path and file name can be changed using the Save Report Window. In order to save the file to the
desired location, click [Save].
55
Haultronics
Before proceeding:
• Ensure that all general settings are saved into the CCU.
• Need to have the front and rear rim and tire type information available.
• Need to have the truck net scale weight in kg, measured empty and free of dirt available.
NOTE: If truck net scale weight is not available the default net weight based on vehicle model is
reasonable for use but the measurement accuracy will decrease. Default net weights are displayed when
you click the [Info] button in the Haultronics – Settings and Calibration Window.
Haultronics Calibration
1. From the main menu select [Haultronics]-[Calibration and Settings] and the Haultronics – Settings and
Calibration Window will open:
2. Click the [Read] button.
3. Verify if the tire and rim information is correct. If not click the [Edit] button and select the proper rims or
tires using the Tires and Rims Window.
4. Check the [Edit] check box found in the “Scale Net Weight” information group. This will allow the scale
net weight to be edited.
5. Type in the empty measured scale net weight in kg.
56
Haultronics Calibration (Continued)
6. Click the [Calibrate] button, the Calibration Window will open displaying calculated Haultronics
parameters, see the picture below.
7. Click [Yes] to write the Calibration to the CCU.
8. Go to Haultronics Settings (later in this section).
NOTE: If the truck is already calibrated and you only want to read the calibration parameters and save
them to a file, the following 3 parameters will show as N/A:
• Front Standard Intercept

• Rear Standard Intercept
• Standard Empty Weight
These parameters are only used in calculations and unless a calibration is performed they are not
available to read.
57
Haultronics Settings
Click the [Settings] tab to switch to the Settings Page. See the picture below:
This page contains 3 settings that are related to the Haultronics system.
1. Maneuvering Distance: The maneuvering distance represents the distance traveled before entering the
“Final” payload state. This distance is monitored from the moment when the truck first moved while is in
“Loading” state. Range:
• minimum 10 m
• maximum 160 m (recommended)
After the vehicle traveled the entire maneuvering distance, automatically enters the “Final” payload state.
2. Final Payload Calculation Time: Represents the number of seconds necessary to calculate the final
payload. Range:
• minimum 10 sec
• maximum 60 sec (recommended)
This setting will influence the accuracy of the final payload calculation. The maximum value will provide
maximum accuracy.
3. Overload Up-shift Restriction: This setting applies only for EH1700-3. If this setting is enabled it will
prohibit the vehicle to up shift gears when overloaded. The [Default Values] button sets the
maneuvering distance and the final payload calculation time to maximum and turns off the Overload up-
shift restriction.
Load weight light threshold settings are also displayed on this page but not editable.
58
Write the settings:
After selecting the maneuvering distance and final payload calculation time click the [Write Settings] button.
Save to file and report:
Click the [Save to File] button to save the calibration/settings details to a text file. Follow the save instructions
found in the Save to File Window. Click the [Report] tab to see the content of the file.
Save the CCU settings:
After settings and calibration are performed turn OFF the vehicle contact key then wait for at least 15 seconds to
allow the CCU to transfer the settings into the permanent flash memory.
NOTE: Do not proceed to Final Preparation if this step is not performed.
Final preparation:
There are two more settings to perform before using the vehicle:
1. Delete all records: Open the Haultronics Download Window by selecting [Haultronics]-[Download
Records] from the main menu. Click the [Delete all Records] button and confirm the action. See picture
below.
2. Reset the current Haultronics cycle to “Empty”: Start the vehicle. Lift the body up and then lower the
body.
3. Store settings into the flash memory: Turn the Ignition Switch OFF and wait for 15 seconds to allow
settings to transfer to the CCU flash memory.
THE TRUCK IS NOW READY FOR USE!
59
Downloading Haultronics Records
Download
• Open the Haultronics Download Window by selecting [Haultronics]-[Download Records] from the main
menu.
• Click the [Download] button. If the record Log is empty a popup message will confirm that, otherwise the
download is started.
• After the download is finished the records are shown in the textbox found in the Haultronics Download
Window.
• While downloading it is recommended to avoid other computer actions.
• A progress bar found in the status bar will indicate the download status.
Save to File
• After downloading click the [Save to File] button and follow the save instructions found in the Save to
File Window.
Delete Records
NOTE: It is recommended to save the downloaded records to a file before deleting the records.
• Click the [Delete All Records] button and confirm the action. At the end of the delete action a popup
message will confirm if the delete was successful.
• To finalize the delete action, turn the Ignition Switch OFF and wait for 15 seconds.
NOTE: The maximum number of Haultronics records is 1350, each record corresponding to a full cycle. If
the maximum number of logs is exceeded the system will start to overwrite records from the beginning of
the log until the log index becomes 65,535 when it will reset the log causing the loss of previous data.
Warning Flags
Flag Description
0000000000000001 Dumping during final stage
0000000000000002 Dumping during maneuvering stage
0000000000000003 N/A
0000000000000004 Overloaded
0000000000000005 Overloaded and dumping during final stage
0000000000000006 Overloaded and dumping during maneuvering stage
60
Haultronics Lights
There are two internal and two external Haultronics lights. The internal lights are found in the cabin and the
external lights are located on each side of the upper deck. The purpose of the lights is to indicate the payload
status in order to prevent overloading. The following table describes the behavior of the Haultronics lights:
Lights Percent of Nominal

Amber Red Payload
OFF OFF < 70%
Flashing OFF 70% to 95%
ON OFF 95% to 110%
OFF Flashing 110% to 120%
OFF ON > 120%
Flashing Flashing System Error
NOTE: A system error is displayed if any of the following problems are present:
• Any strut pressure error reading

• Body angle error reading
• Inclinometer error reading (vehicle Y axis incline)
In case of system error the Haultronics system is deactivated.
61
Advanced Panel
To open the Advanced Panel Window select [Contronic]-[Advanced Panel] from the main menu, as shown in
the picture below:
The following window will pop up:
The Advanced Panel is designed to read various parameters from the CCU. The reading is triggered by either of
the following two buttons:
1. [Read AA]: Where “AA” represents the current page description (i.e. Std. - General, Std. Engine-
Transmission, etc). Clicking this button the software will perform only one reading.
2. [Read Live]: Clicking on this button the software do readings cycles, constantly refreshing the current
page. Once clicked the button description changes into [Stop Read Live].To stop the live reading click
the button one more time, exit the Advanced Panel or the application.
62
The Advanced Panel is grouped in the following 4 Tabs and respective sub-tabs:
1. Standard
• General
• Engine – Transmission
• Electric – Gauge
• Brake – Steering – Hoist
• Warning List
2. Input/Outputs
• Digital Analog Inputs
• Digital Out (Lamp – Solenoid – Relay)
• PWM Out (Gauge – Solenoid)
3. Load Weight
• Haultronics
4. ATC/EDSC
• ATC/EDSC
Advanced Panel Overview:
NOTE: The following terminology applies to the Advanced Panel:
• N/A refers to Not Applicable.

• “All” implies any of the following Warning Level statuses: None, Warning or Alarm can be
indicated in the “Warning Level” column.
• “Info Box” refers to a delimited panel area containing information that is from the same group
category.
Standard Tab - General
This sub-panel provides information about the vehicle CCU settings and current speed, transmission and body
status.
63
The following table details the information found in the [Standard]-[General] tab of the Advanced Panel.
Warning
Info Box Item Description U/M
level
Model
Eng Model
Make
Base Truck identification elements.
Serial Number
Vehicle ID
Unit Number
N/A
Tire Front
Tire Description
Tire Rear
Rim/Tires
Rim Front
Rim description.
Rim Rear
Part Number
CCU Software CCU software identifiers.
Release Date
Max GMW
Net Weight Weigh specifications.
Weight m-ton, s-ton
Max Payload
Payload Indicates the calculated payload.
Vehicle Speed
km/h, mph
Engine speed N/A
Required Gear
Vehicle Info Indicates basic vehicle functional parameters.
Current Gear N/A
Body position
Fuel Level %
Date and Time Indicates the date and time when the CCU yyyy-mm-dd,
Conf Date/Time
software was last configured. hh:mm:ss
Description
Overall Rear
Differential Indicates rear axle ratio specifications. N/A
Axle Ratio
Planetary
Travel Distance km, miles
Engine Hours
Operation Indicates operational specifications.
Vehicle Hours hours
Vehicle Idle
Sound
Suppression
Options Hill Hold Indicates available options and the status. On/Off
Haultronics
Water Truck
64
Standard Tab - Engine and Transmission
This sub-tab provides general Engine and Transmission information.
• The [Reset Log] button can be used to reset the Engine Log.
• The [Diag Code] button allows the display of diagnostic codes that are broadcasted by the engine or
transmission as shown in the following picture:
NOTE: Some codes may not be displayed due to CCU software pre-configuration.
65
The following table details the information found in the [Standard]-[Engine – Transmission] tab of the
Advanced Panel:
Warning
Level
Speed Indicates the engine speed. rpm
Oil Pressure Indicates the engine oil pressure. MPa, bar, psi
Oil Temperature Indicates the engine oil temperature. All
Coolant Indicates the engine coolant temperature. C, F
temperature
Fuel Level Indicates the vehicle fuel level.
%
Throttle Position Vehicle throttle pedal position.
Low Pressure Time of operation while low oil pressure
High Temperature Time of operation while high oil temperature. N/A
Engine Hours
Air Filter Time of operation with active air filter
Restriction restriction.
Speed Limit Indicates the engine speed limit. rpm
Coolant Level Engine coolant level warning.
Air filter one Engine air filter one warning.
Air filter two Engine air filter two warning. All
N/A
Service Engine service warning.
Data link loss Engine data link loss warning.
Diagnosis Code Engine and Transmission codes N/A
Oil pressure Transmission oil pressure. MPa, bar, psi
All
Oil Temperature Transmission oil temperature. C, F
Output Speed Transmission output speed. rpm
Required Range Transmission required range.
N/A
Transmission Current Range Transmission current range.
Lockup Transmission mode (Converter or Locked).
N/A
Oil Filter Transmission oil filter warning.
All
Data link loss Transmission data link loss warning.
Diagnosis Code Not available. N/A
66
Standard Tab – Electric / Gauge
This sub-tab provides general Electrical and Gauge information.
The [Reset Log] button can be used to reset the Electric log.
The following table details the information found in the [Standard]-[Electric-Gauge] tab of the Advanced Panel:
Warning
Level
Key Status Indicates the contact key status. N/A N/A
Alternator Voltage Indicates the alternator output level.
System Main 24V Indicates the CCU main power level.
CCU Sensor 5V Supply Indicates CCU sensor 5V output level. Volts All
Electric
CCU Sensor 24V Supply Indicates CCU sensor 24V output level.
CCU Internal Battery Indicates CCU internal battery level.
System Over 31V
Time operating with high alternator output. seconds N/A
System Over 40V
MPa, bar,
Brake/Steer Pressure
psi
Fuel level %
Engine Coolant Temp
Gauge Indicates dash board gauge values. N/A
Transmission Temp C, F
Brake Temp
Tachometer rpm
Vehicle Speed km/h, mph
NOTE: The Gauge information is no longer available due to redundancy with the LCD dash panel.
67
Standard Tab – Brake/Steering/Hoist
This sub-tab provides detailed information about the Brake, Steering and Hoist systems.
The [Reset Log] button can be used to reset the Brake log.
The following table details the information found in the [Standard]-[Brake-Steering-Hoist] tab of the Advanced
Panel:
Warning
Level
MPa, bar,
Brake Oil Pressure Brake oil pressure All
psi
Brake Oil Temp Brake oil temperature C, F
Park Brake Status Park brake status On/Off
Brake Park Brake Pressure Park brake pressure warning N/A
Brake Oil Pressure Low Time operating while low brake pressure.
Brake Oil Temp High Time operating while high brake temperature. min N/A
Park Brake Request Time while vehicle moving with park brake
While Moving request (park brake switch On).
Level Position Hoist lever position. % All
Level Status Hoist lever status (Up, Hold, Float, Down, Err) N/A
Body Angle Body angle value. % N/A
Hoist Body Position Body position (Up, Down or Err)
N/A
Oil Filter Status Hoist oil filter status (normal or clogged) All
Maximum Angle Indicates the body up limit in percent.
% N/A
Calibration Coefficient Hoist calibration coefficient.
Steering oil pressure. Same as brake oil MPa, bar,
Oil Pressure All
pressure. psi
Steering
Oil Pressure Status Steering oil pressure warning status. N/A N/A
Oil Temperature Steering oil temperature. C, F All
68
Standard Tab – Warning List
This sub-tab displays a list of active warnings.
The following table details the information found in the [Standard]-[Warning List] tab of the Advanced Panel:
Warning
Level
Warning List Warnings Indicates a summary of all current active warnings. N/A All
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Input/Output Tab – Digital/Analog Input
This sub-tab provides detailed information about the digital, analog and pulse inputs.
The following table details the information found in the [Input-Output]-[Digital/Analog Input] tab of the
Advanced Panel:
Warning
Level
Analog inputs Line 1 to Line 24 Various input signal voltage level. Description
Volt
Digital Inputs Line 1 to Line 24 varies based on truck models. N/A
Pulse Input Input 1 to Input 4 Frequency inputs, indicating wheel speed Hz
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Input/Output Tab – Digital Outputs (Lamp-Relay-Solenoids)
This sub-tab provides detailed information about the lamp, relay and solenoids outputs.
The following table details the information found in the [Input-Output]-[Digital Out (Lamp-Relay-Solenoid)] tab
of the Advanced Panel:
Warning
Level
Current sink outputs, max 0.1A. Description varies
Lamp Line 1 to Line 29
based on truck models.
Current source outputs, max 0.1A. Description varies
Relay Line 1 to Line 12 On/Off N/A
Current source outputs, max 0.75A. Description varies
Solenoid Line 1 to Line 4
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Input/Output Tab – PWM Outputs (Gauge-Solenoid)
This sub-panel provides detailed information about the PWM outputs (gauge and solenoids).
NOTE: The Gauge information applies only for the older instrument panel, where gauges are
commanded by the CCU directly using PWM signals.
The following table details the information found in the [Input-Output]-[PWM Out (Gauge-Solenoid)] tab of the
Advanced Panel:
Protect/Channel
Status
Fuel
Brake Temp
Output pulse width modulates
Eng Coolant Temp
Gauge signals. Modulation indicated in % N/A
Transmission temp percent.
Speedometer
Gauge 6
Body Up
Body Down
Left Brake Operational,
Output pulse width modulates
Right Brake Short,
Solenoid signals. Modulation indicated in %
Solenoid 5 Not Active,
percent.
Solenoid 6
Steer Brake Oil Press Gauge
Tachometer Gauge
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Load Weigh Tab - Haultronics
This sub-tab provides detailed information about the Haultronics system.
The following table details the information found in the [Loadweigh]-[Haultronics] tab of the Advanced Panel:
Warning
Level
Front Left Pressure
Front Right Pressure MPa,
Indicates the strut pressure All
Rear Left Pressure bar, psi
Strut - Inclinometer
Rear Right Pressure
Inclinometer X
Indicates the incline value %
Inclinometer Y
Possible stages: Empty, Loading,
Stage Maneuvering, Final, Haul, Dumping, N/A
After Dumping, Tare,
Status N/A
m-ton,
Payload Current payload (static or final)
s-ton
Buckets Current number of buckets
Red Indicates loading status. On/Off and N/A
Lights
Yellow flashing
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ATC - EDSC Tab
This sub-tab provides detailed information about the ATC and EDSC system.
The following table details the information found in the [ATC-EDSC] tab of the Advanced Panel:
Warning
Level
Vehicle Speed Vehicle current speed. km, mph
Rear Wheel Left Rear wheel speed km, mph,
Speed Rear Wheel Right rpm
Control to select for display km/h instead
Check Box [km/h] N/A
rpm where applicable.
Rear Left Brake Indicates the level of braking in percent.
%
Rear Right Brake N/A
ATC ATC Active Indicates if ATC is active
ATC Boost Indicates if ATC Boost is active On/Off
ATC Error Indicates if ATC error.
Set Speed Indicates the set control speed for EDSC. km, mph
Retard Brake Torque Indicates the level of braking in percent. %
EDSC
EDSC Active Indicates if EDSC is active
On/Off
EDSC Error Indicates if EDSC error
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Help panel
The Help feature is not available in this software revision. It will be added in future revisions. Select [Help] from
the main menu and the following message will pop up:
About Panel
Select [Help]-[About] from the main menu and the About Service Tool Software Window will pop up:
This window describes the software version and release date, in the [Software Info] text box.
The [Computer Info] box contains basic operating system and computer hardware information.
Exit the application

To exit the HTM Service Tool application select [File]-[Exit] from the Main menu, or click [X] in the top right
corner of the main application window.
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WinLoader3
Winloader3
Installing WinLoader3
The WinLoader3 software is used to upload software to the Hitachi LCD instrument panel. WinLoader3 software
can be downloaded from the Service e-Cabinet on Global e-Service. If the WinLoader3 software is already
installed on the computer being used for LCD Instrument Panel software uploading you can skip this section.
1. Extract the files contained in WinLoader3.zip into a new folder

2. Run the file Setup.exe found in the “package” subfolder of the newly created folder
3. Click the [OK] button in the “Setup Toolkit” screen
4. Click the [OK] button
5. Click the Installation button
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Installing WinLoader3 (Continued)
6. Click the [Continue] button
7. Click the [OK] button to finish the software installation.
Installing the USB to CAN adapter driver

To use the WinLoader3 software program it is necessary to use a USB to DB9 CAN adapter cable. In the
contents of the Software Kit (Part Number E12650910PXX) there is a driver CD labeled “PEAK system”.
1. Insert the CD labeled “PEAK System” then click the [English] button
77
Installing the USB to CAN adapter driver (Continued)
2. Click the [Drivers] button
3. Enable the check box corresponding to the PCAN-USB device then click the [Install Now] button
4. Follow the driver installation program, click the [Next] button
78
5. Agree with the License Agreement by selecting the [I agree…] check box and then click the [Next]
button
79
9. Choose the user access level then click the [Next] button
80
11. Wait until the installation is complete as indicated in the picture bellow:
12. Click the [Finish] button to complete the installation
13. Click the [OK] button to restart your computer
81
Programming the Hitachi LCD Instrument Panel
1. Identify the J1939 vehicle communication port
2. Connect the USB to DB9 CAN adapter and the DB9 to J1939 cable
3. Connect the programming cable to the J1939 port and the laptop USB port
4. Turn the Ignition Switch OFF
5. Run the WinLoader3 software application from the Start Menu or double click the icon found on the
computer desktop. The following window will be displayed:
6. Click the [Start Bootloader] button
82
Programming the Hitachi LCD Instrument Panel (Continued)
7. When the following message window appears, turn the vehicle Ignition Switch ON
8. Click the [Update Flash] button
9. Select the file to be downloaded into the Hitachi LCD Instrument Panel using the browse window as
indicated below, then click the [Open] button
NOTE: The file name shown in the picture above is an example only.
10. The Progress Window will appear, wait until the programming is finished
83
Programming the Hitachi LCD Instrument Panel (Continued)
11. After the programming is finished click the [Restart Application] button to restart the panel
12. Close the WinLoader3 application. The Hitachi LCD panel is reprogrammed and running
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Troubleshooting
Troubleshooting
This section is a quick reference on troubleshooting communication problems with the Contronic/Haultronics III
Software, HTM Service Tool and Flash Development Toolkit (FDT); it is not intended as an all encompassing
troubleshooting document. It will guide you through some settings you can check if you are experiencing
difficulties communicating with the Hitachi CCU when using the HTM Service Tool Program. Additional problems
may exist that are not covered in this document.
Contronic/Haultronics III Communication Errors
If you receive a communication error message from the Contronic/Haultronics III Software when you start the
software program, click [OK] to continue opening the software program then verify the following:
• The download cable is connected properly

• The Ignition Switch is ON
• Check to ensure the software and cable are using the proper COM port. To do this select [Tools]-[Set
Communications] from the Contronic/Haultronics III main menu. The Communication Settings Window
will open and display the software program settings. Confirm the COM port settings on your laptop, see
“Selecting a COM Port” later in this manual section.
FDT Communication Errors
If you are receiving a communication error message from the FDT software when pressing the [Connect] button
on the communication screen verify the following:
• RS232 cable is properly connected. The 9-pin data connection at the rear of the truck does not have a
screw-on connector and can disconnect easily.
• Ignition Switch is turned all the way to the ON position, (dash lights and radio on).
• Programming Key Switch is in position 1
• The LED on the CCU is not flashing.
• Communications settings are set as outlined under “Programming the CCU” in the “FDT Software”
section.
• You have the proper COM port selected on your PC, (See “Selecting a COM Port” later in this section).
85
• The cable in use is not faulty.
NOTE: Many Laptops no longer come equipped with 9-Pin serial ports requiring you to use of an adapter
to communicate with the CCU using the RS232 interface. Communication issues with RS232 adapters
are known to exist. If you are using a USB or PCMCIA to RS232 adapter, it may not be possible to
communicate with the CCU using the FDT software. If you are experiencing communication issues you
are unable to resolve when using any sort of RS232 adapter you may need to use a laptop with a 9-Pin
serial port.
HTM Service Tool Communication Errors

When using the HTM Service Tool it is possible to receive two different types of Communication Error Message.
1. COM Port error message:
If you receive this error message, ensure:
• Your PC COM port settings match those of the HTM Service Tool, (See “Selecting a COM Port” later in
this section).
2. Communication Error message:
If you receive this error message, ensure:
• RS232 cable is properly connected. The 9-pin data connection at the rear of the truck does not have a
screw-on connector and can disconnect easily.
• Ignition Switch is turned to the ON position, (Do Not start the engine).
• Programming Key Switch is in position 0
• The LED on the CCU is flashing.
• Communications settings are set as outlined under “Communication Settings” in the “HTM Service Tool”
section.
• The cable in use is not faulty.
NOTE: Many Laptops no longer come equipped with 9-Pin serial ports requiring you to use of an adapter
to communicate with the CCU using the RS232 interface. Communication issues with RS232 adapters
are known to exist. If you are using a USB or PCMCIA to RS232 adapter, it may not be possible to
communicate with the CCU using the HTM Service Tool software. If you are experiencing communication
issues you are unable to resolve when using any sort of RS232 adapter you may need to use a laptop
with a 9-Pin serial port. Communication issues when using a RS232 adapter with the HTM Service
Tool are less frequent then when using an adapter with the FDT. Many USB to Serial adapters will
work with the HTM Service Tool without any problems.
86
Selecting a COM Port
Follow the directions below to change your PC COM port settings.
1. Open the System Properties Window for your computer by right-clicking on the [My Computer] Icon and
selecting [Properties].
2. Select the [Hardware] tab from the System Properties Window and click [Device Manager].
87
Selecting a COM Port (Continued)
3. A list of devices will appear. Find “Ports”, click the [+] checkbox to expand the list and see all ports in
use. Select the port you wish to set-up for communication by double-clicking on it; this will open the
Properties Window for that port.
4. On the Communications Port Properties Window, select the [Port Settings] tab. The settings shown
must match the settings found on the communication screens of either the HTM Service Tool or FDT
software.
5. After changing the settings to match press the [Test] button on the HTM Service Tool Communication
Window or the [Connect] button on the FDT Communication Window to test the new communication
settings.
88
Selecting a COM Port (Continued)
6. If problems still exist click the [Advanced] button to open the Advanced Settings Window for the COM
port.
7. The Advanced Settings Window will allow you to adjust the “Buffer Settings” for the COM port. Adjust the
Buffer settings to the lowest value to help with connection problems.
NOTE: If these steps do not correct your communication problem, you may have a hardware issue,
(cable, port), or other problems may exist that require the attention of Hitachi Truck Product Support
Personnel. Contact your Hitachi Truck Product Support Representative.
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Publication Number: HTT-32-0109

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7. Click [Download] on the Software file.

• Notebook Computer (Laptop) with:

Contronic/Haultronics III Software

• Construction Truck Contronic/Haultronics III Software Part Number: E12656685PXX

• Mining Truck Contronic/Haultronics III Software Part Number: E12647671PXX

Rewriting the ECU Program

ECU Programming Setup

Programming the ECU

NOTE: If the “L>” prompt doesn’t appear, there is a communication problem:

• Check the cable connection

NOTE: DO NOT select [Send Text File]

11. Once you have found the file click [Send]

14. When the “L>” prompt re-appears, the programming is done

15. Turn the Ignition Switch OFF

Upgrading From Prior Versions of Contronic/Haultronics Software

2. The Contronic/Haultronics Software program currently installed must be removed:

• From the Windows Start menu select [Control Panel]-[Add/Remove Programs]

Installing Contronic/Haultronics III

6. An Open File – Security Warning Window will open, click [Run]

Contronic/Haultronics III System Calibration

13. Click [Quit] to finish the truck calibration.

5. Click the [Read] button to display current truck option settings:

3. Flash Development Toolkit (FDT)

Flash Development Toolkit

HTM Service Tool

• Construction Truck Service Tool Part Number: E12659907PXX

• Mining Truck Service Tool Part Number: E1265493PXX

Example S19 software file name: 60-UD-82180-107-BTL

Installing Flash Development Toolkit

12. Double click FDT15.exe. Click the [Next] button

13. Click the [Yes] button.

14. Click the [Next] button.

16. Click the [Next] button.

17. Click the [Next] button.

18. Click the [Next] button.

20. Select SH/7055F. Click the [Next] button.

21. Click the [Finish] button to complete the installation

CCU Programming Setup

Programming the CCU

4. Select the communication settings as indicated in the following:

• Turn Ignition Switch OFF

Obtaining the HTM Service Tool Software

• From the Windows Start menu select [Control Panel]-[Add/Remove Programs]

1. Click the [Next] button.

NOTE: If installing the software on a shared laptop ensure “Everyone” is selected.

Figure 3: HTM Service Tool Log-in Screen

There are three “User Modes” available:

• No password required, provides read only features.

• Requires a password and is reserved for engineering use.

Figure 4: HTM Service Tool Main Screen

3. Select the COM port connected to the CCU.

• The [Test] button verifies the communication.

4. Once settings are complete click the [Test] button.

2. The Application Settings Window will open:

• Choices for units of measure are shown in the table below:

Units Temperature Speed Distance Pressure Weight

These parameters are grouped by functional categories.

The Standard Panel Window will open:

Initial Standard Panel status:

• All fields are empty and disabled

• Model – The vehicle model (selectable from a list)