I have had the same problem with the Online repair from here in the States, it seems there was a problem with my address. I have learned that their
page only accepts certain address elements, rejects others, and often will not tell you what the problem is.
Eventually, I called the toll free number, and a real live person helped me, even though the recording said they would only help with specific problems, and my Zune 120 had an entirely different set of issues.
As far as the problem with your Zune, I don't know, I have the same problem with my Zune 80, (out of warranty) and don't know the a fix for it (hence the Zune 120).
For what it's worth, I've let the battery drain, and recharge a few times. One time it did get to Screen 5 (Call customer service), but I blew that it and pushed a button or two.
Give the fine folks at Zune Support a call (1-877-438-9863, you probably have to dial 01 or 011 before the 877.) It's toll free from the US, I dunno about from Japan, though.
And, BTW, thank you for your service. Be as safe as possible.
Poppa1956. yeah.