Toyota Flashware

User Guide

7HBW23/7BWS10 8HBW23/8BWS13
8HBE 8BNCU
8HBC 7BPUE15
8HBW 8BPU
8TB50 9BRU

1
 Table of Contents

Introduction 3

Download from TIS and Installing Flashware 5

Installing the .s19, .s37, and .cbf Files 10

USB to CAN Driver Install 13

7HBW23 Walkie and 7BWS10/13 Stacker 14

7BPUE15 Orderpicker 18

8BPU Orderpicker 27

8HBE30/40, 8HBW30, 8HBC30 Walkies and 8TB50 Tuggers 30

8BNCU Stand Up Counterbalance 34

9BRU Reach 37

8HBW23 Walkie and 8BWS10/13 Stacker 40

2
 Introduction

Toyota Flashware is a program that runs on a laptop computer. Flashware is used to install
and update Vehicle Manager Software, change Configuration, run Diagnostic procedures, and
run Calibrate. It is available on the Toyota Technical Information System (TIS) website on the
Dealer Portal.

There are two downloads from TIS that need to be performed. The first download is the
Flashware program file and the second is the .s19, .s37, .cbf, and .psu files - the software files
the forklift uses to operate, which will need to be installed into Flashware. Those procedures
will be explained in a later section. Pictured are the cables and adapters required to connect
the laptop to the forklift:

9 Pin Serial to 9 Pin Serial USB to 9 Pin Serial

Used on the 7BPUE15 Orderpicker Used to the 9 Pin Serial to the laptop

00590-43591-71 00590-49958-71

3
USB to CAN Adapter CAN Adapter to Walkie

Used on all Walkies Used on all Walkies

00590-47758-71 00590-42684-71

USB to USB

Used on the 8BNCU, 8BPU15, 8BPUE15

8BPUH15, 9BRU18, 23 & 9BDRU13, 15

00590-49955-71 (5 to 7 feet)

00590-49956-71 (8 to 12 feet)

00590-49957-71 (13 to 20 feet)

4
 Download from TIS and Installing Flashware
Flashware program files are located on TIS in Software Downloads. Left click on Software
Downloads, Screen 2 appears. Left click Download on the Flashware vx.x tab. Select “Save As”
on the “Save” drop box and Screen 3 appears. Select “Desktop”. Click on “Save”. See Screen 3.

Screen 1

Left click Software

Downloads

Screen 2

Flashware vx.x
Left click on the
Download tab
Save drop box and
select Save As

5
 Screen 3

Desktop Tab

Click save

Download the “.s19”, “.s37”, and “.cbf” files following the same procedure used to download
Flashware vx.x program. Reference Screens 2 & 3

Screen 4

s19, s37 and

cbf files
Download tab

6
 There will be two “zipped” or compressed folders on the desktop of the laptop computer.

Screen 5

Right click on the zipped folders (Screen 5) and select “Extract All”. Follow the screen
prompts to extract the files. Screen 6

Screen 6

7
After the files have been extracted, there will be two folders labeled “Flashware vx.x” and
“Flashware .s19 and .cbf files” on the desktop that are not compressed, or are without a
“zipper” on the folder. (See Screen 7) DO NOT OPEN the folder with the .s19 and .cbf files. If
opened by the laptop computer, the files will be corrupted and the forklift will not work
properly. Those are the Vehicle Manager and Traction Amplifier software files. The procedure
for those will be discussed in a later section.

Screen 7

8
Double click on the “Flashware vx.x folder and there will be three .pdf files and an Application
“.exe” file. Double click the Application file and install Flashware by following the Install
Wizard. (See Screen 8) When completed, a flashbulb icon will be displayed on the desktop.
(See Screen 9)

Screen 8

Screen 9

9
 Installing the .s19, .s37, and .cbf Files
There should be a folder on the desktop without a “zipper” labeled .s19 and .cbf files.
DO NOT OPEN THE FILES. These are the previously mentioned downloaded and extracted files.
If they are not on the desktop, repeat the procedure of downloading from TIS and extracting.
Open the Flashware program and select the “Files” tab on the left hand side. A drop down
menu will appear. Select “Install Software into Flashware Directories.” See Screen 10.

Screen 10

Double-click “Install Software into Flashware Directories”, and the following screen will
appear. On the left hand side, select Desktop. This is where the files should have been saved.
The folders with the .s19 and .cbf files will be located here. See Screen 11.

Screen 11

10
Double click on the folder. The following screen will appear. There will be multiple folders
shown for different model forklifts. See Screen 12.

Screen 12

For an example, double click on the “8 Series Class III electric brake software files” and the
following appears. See Screen 13.

Screen 13

11
Continuing the example, double click on the “Model 915A (8HBC&TB50 Electric Steer)” folder
and the following appears as shown in Screen 14. The file to be installed into Flashware has a
“whiteboard” beside it and an .s19, .cbf, or a .psu extension behind it. Highlight the file and
the click the “Open” tab.

Screen 14

This procedure needs to be done one file at a time for every file. The .s19 files are for the
Vehicle Manager, the .cbf files are for the Traction Amplifiers, and the .psu files are for the
Power Steering Units. Keep track of the files as they are downloaded. If duplicated, a message
will appear that the file has already been downloaded. If a file is missed, there is no such
message. Every file will need to be downloaded to make sure the laptop can download every
Vehicle Manager, Traction Amplifier, and Power Steering Unit software file if it is needed.

12
 USB to CAN Driver Install
The USB to CAN driver is used for the adapter that connects the laptop to a truck that requires
an ETAC card, such as the 7HBW23 and 8 Series Walkies and Tuggers. Before performing this
procedure, ensure there is nothing in a USB port, including the adapter. Click on the “File” tab
on the left side of the Flashware program and then select “Run USB to CAN Driver Install” tab.
See Screen 15.

Screen 15

Follow the install prompts to the finish. See Screen 16. After the USB to CAN driver is
installed, plug in the USB to CAN adapter into a USB port. A dialog box that says “Installing
Device Driver Software” will appear on the screen. See Screen 17. The laptop computer is
now ready to connect to the forklift.

Screen 16 Screen 17

13
 7HBW23 Walkie and 7BWS10/13 Stacker
Flashware is used on the 7HBW23 and 7BWS10/13 to install Vehicle Manager software in a
new ETAC card, re-install Vehicle Manager software in an existing ETAC card, change Configure
settings, and perform diagnostics. The USB to CAN adapter and walkie cable are needed to
connect the laptop to the forklift. When the ETAC card is replaced with a new card it comes
blank, with no software installed. The forklift will not operate and “test” will show on the
dislay. Flashware is used to download or install the Vehicle Manager software. After you
connect to the truck, the software screen will be the first screen to appear. See screen 18.

Screen 18

Vehicle
Manager

Truck Software Screen

Highlight the Vehicle Manager as the device and the box on the lower left will populate with
software versions. Highlight the correct sofware version and click on the tab “Load Device
with Selected Software Version”. See screen 19.

14
 Screen 19

Load Device
with Selected
Software
Version

91540010.s19

Truck Software Screen

Follow the prompts that appear on the screen. After the software is loaded, the Truck Setup
screen will appear. The correct serial number and date of manufacture (year only) will need to
be installed. Put the cursor over the serial number box and type in the serial number. Do the
same for the date of manufacture. After the correct date and serial number are entered, click
on “Send Changes to the Truck”. Follow the prompts on the screen. Flashware will re-connect
and the Truck Setup screen will appear with the correct serial number and date of
manufacture. See screen 20.

15
 Screen 20

Truck Setup Screen

Flashware can be used to change the parameters for the forklift. Find the parameter that
needs to be changed, change it and then click on send changes to the truck.

Flashware can also be used for diagnostic purposes. Click on the Diagnostics tab on the right
hand side of the Truck Setup screen. A diagnostics screen will appear. See screens 21 and 22.
Screen 21 shows the green ovals or “jelly beans” lit up from the speed request lever and the
lower request lever. These are inputs from the Vehicle Manager or ETAC card. Screen 22
shows the inputs and outputs from the Traction Amplifier. There are also drive motor current
and PWM values in the Traction Amplifier section.

INP pin 14: Arm Angle B INP/OUT pin 5: Brake Coil

INP pin 12: Arm Angle A OUT pin 7: Horn

INP pin 15: Lift Limit Interlock: Main Contactor

INP/OUT pin 2: Lower Valve OUT pin 6: Lift Contactor

16
 Screen 21

Jellies showing
speed request

Jelly showing
lower request

Screen 22

Arm Angle B

Lift Contactor Lift Limit

0= no lift 1=lift
1=lift 0=no lift

Arm Angle A
Horn
0=silent Lower Valve
1=sounds 1=holding
0=lower

Brake Coil
Main
1=brake applied
Contactor
0= brake released

17
 7BPUE15 Orderpicker
Flashware is used on the 7BPUE15 to change Configuration or Option settings, install or
update the Vehicle Manager software, or perform Diagnostics. USB to serial adapter and the 9
pin serial cable are needed to connect to the Orderpicker. The port is located on the Steer
Tractor Manager.

When Flashware is connected to the forklift, the first screen to appear is the Truck Setup
Screen. See Screen 23.

Screen 23

Truck Setup Screen

It is from this screen that changes to Configuration or Options can be made. To make a
change, click on box for the desired option. After the changes have been made, click on “Send
Changes to Truck” and follow the prompts on the screen. Some options will require hardware
components to be installed on the forklift to function correctly.

18
It is from this screen that the Primary Memory can be cleared. The Primary Memory is the
Carriage Card. Clear Primary memory is used if Carriage Cards are swapped between different
orderpickers. Use the “Clear Primary Memory” tab on the right hand side.

It is also from this screen the Vehicle Manager can be cleared. The Vehicle Manager is the
Steer Tractor Manager in the tractor end of the forklift. Clear Vehicle Manager can be used if
the Steer Tractor Manager cards are swapped between different orderpickers.

Screen 24

Software Screen

Screen 24 is the Software screen. To install Vehicle Manager Software, highlight the software
model number to get the version you want to install. Highlight the version number, and then
click on “Load VM with Selected Software Version”. Follow the prompts on the screen to
finish the process.

19
The following are Diagnostic Screens. The diagnostic screens show live data. There are
different tabs for different systems on the forklift. The screens show different inputs and
outputs and points on the forklift to measure and confirm the results.

Screen 25

Events and Codes tab at key on, deadman pedal not depressed.

Screen 25 shows the Events and Codes tab with no inputs. If the forklift has active error codes,
this is where they will be displayed.

20
 Screen 26

Safety tab with no active inputs

Screen 26 is the “Safety” tab. Data is divided into “Input Signals” and Output Signals”. The
two left side columns are the components and the components current status. The right side
columns are what the meter readings should be at the pin shown. All voltage measurements
are with respect to TP4 or battery negative.

21
 Screen 27

Lift tab with no inputs, lift knob in neutral

Screen 27 displays data available on the “Lift” tab under the Diagnostics window. Data is
divided into “Input Signals” and “Output Signals”. The two left columns show the components
and the components current status. The two right columns show what the voltages should be
and from where to make the measurements. All voltages are made with respect to TP4 or
battery negative. The lift potentiometer value shows the current value and in parenthesis the
calibrated value. It is a calculated value and not what your voltmeter will read.

22
 Screen 28

Steer tab with no inputs

Screen 28 displays data available on the “Steer” tab under the Diagnostics window. Data is
divided into “Input Signals” and “Output Signals”. The two left columns show the components
and the components current status. The two right columns show what the voltages should be
and from where to make the measurements. All voltages are made with respect to TP4 or
battery negative. Note that there are two encoders shown in the input section. The top one is
for the steering wheel and the other one is the feedback encoder on the drive unit. The
feedback encoder is used to determine the drive unit position.

23
 Screen 29

Travel tab after stepping on the deadman

Screen 29 displays data from the “Travel” tab under the Diagnostics window. Data is divided
into “Input Signals” and ‘Output Signals”. The two left columns show the components and the
components current status. The two right columns show what the voltages should be and
from where to make the measurements. All voltages are made with respect to TP4 or battery
negative. The travel potentiometer shows the current value and in parenthesis the calibrated
value. It is a calculated value and not what your volt meter will read.

24
 Screen 30

BSOC tab

Screen 30 is the Battery State of Charge, or the BSOC tab. It shows the current battery state of
charge, which is measured after the deadman pedal is depressed. It also shows two values
that can be changed to alter the way the battery state of charge is calculated.

25
 Screen 31

Learn Screen

Screen 31 shows the “Learn” screen. Highlight the device that needs learned. Then click on
the tab “Exit and Save Learned Values”.

26
 8BPU15 8BPUE15 8BPUH15 Orderpicker
Flashware is used on the 8BPU Orderpickers to install or update Vehicle Manager, Power
Amps, or change option settings. To connect a laptop computer, use the USB to USB cable.
The port is located on the Vehicle Manager. When Flashware is connected to the forklift, the
first screen to appear is the Truck Setup screen. See Screen 32.

Screen 32

Truck Setup Screen

To change truck options, click on the box next to the option that needs to be changed and a
check mark should appear. After the box is checked or unchecked as needed, click on “SEND
Changes to Truck” and follow the prompts on the screen. Component hardware on the forklift
may need to be changed for the forklift to function correctly. Also on this screen are two tabs,
one for Vehicle Manager Software and Other Device Software. Click on the one needed and
the Software Screen will appear. See Screen 33 & 34.

27
 Screen 33

Vehicle Manager Software Screen

Screen 33 shows a Vehicle Manager Software screen. Highlight the software model number
and the different versions available will appear. Select the needed software version and then
click “Load VM with Selected Software Version” and follow the prompts on the screen.

28
 Screen 34

Other Device Software Screen

Flashware is used to load the Carriage Control Card or the Power Amplifiers. On the Truck
Setup screen click on the “Other Device Software” tab and Screen 34 will appear. Highlight the
needed software version and then click on “LOAD with selected software version”. Follow the
prompts on the screen to finish the procedure. Guidance Manager Software is loaded from
this screen if the unit is equipped with wire guidance option.

29
 8HBE30/40 8HBW30 8HBC30 Walkies and 8TB50 Tuggers
Flashware is used on the 8 Series walkies and tuggers to change Parameters or perform
Diagnostics. To connect the laptop computer to the forklift, use the USB to CAN adapter and
walkie cable.

When Flashware is connected to the forklift, the first screen to appear is the Truck Setup
screen. See Screen 35.

Screen 35

Truck Setup Screen

It is from this screen that changes can be made to Parameter settings. Once the changes have
been made on the screen, click on “SEND Changes to the Truck”. Follow the prompts on the
screen.

30
 Screen 36

Software Screen

When replaced, the ETAC card is blank, with no software installed. The forklift will not operate
and “test” will show on the display. Flashware is used to download or install the Vehicle
Manager software. After you connect to the forklift, the software screen will be the first
screen that will appear. See Screen 36. Highlight the Vehicle Manager as the device and the
box on the lower left will populate with software versions. Highlight the correct software
version and click on the tab “Load Device with Selected Software Version”. See Screen 37.

31
 Screen 37

Software Screen

32
 Screen 38

Diagnostic Screen

Flashware can also be used to run Diagnostics. Screen 38 shows the Diagnostic screen. The
box on the right side is the inputs and outputs to the Traction Amplifier. All the inputs and
outputs are labeled. The boxes on the left side are the inputs to the ETAC card. When the
green jelly bean is lit, it means that input is active. It also shows the battery voltage measured
by the ETAC card.

A walkie that has electric steer will have values for the electric steer components on this page.
Flashware is also used to learn the steer potentiometer values.

33
 8BNCU Stand Up Counterbalance
Flashware is used on the 8BNCU to change truck options and download software. To connect
the laptop computer to the forklift, use the USB to USB cable. When connected to the forklift,
the first screen to appear is the Truck Setup screen. See Screen 39.

Screen 39

Truck Setup Screen

To change truck options click on the option that needs to be changed, and then click on “SEND
Changes to Truck”. Hardware on the truck may need to be changed to ensure the truck
operates properly.

It is also from this screen that you can clear primary memory or clear the vehicle manager.
The primary memory is the display card and the vehicle manager is the back-up memory. Click
on “Clear Primary Memory” or “Clear Vehicle Manager” as needed if you swap components
between different forklifts.

34
 Screen 40

Vehicle Manager Software Screen

Flashware is used to load the Vehicle Manager with software. On the Truck Setup screen click
on “Vehicle Manager Software” and Screen 40 will appear. Highlight the needed software
version number and then click on “Load VM with Selected Software Version”. Follow the
prompts on the screen to finish the procedure.

35
 Screen 41

Display Manager/ Power Amp Software

Flashware is used to load the Display Card or the Traction Power Amps. On the Truck Setup
screen click on the “Display Manager/Power Amp Software” tab and Screen 41 will appear.
Highlight the needed software version and then click on “LOAD with selected software
version”. Follow the prompts on the screen to finish the procedure.

36
 9BRU Reach
Flashware is used on the 9BRU Reach forklift to install or update Vehicle Manager, Power
Amps, or Display software; or change option settings. To connect the laptop computer, use
the USB to USB cable. When Flashware is first connected to the forklift, the Truck Setup
screen appears. See Screen 42.

Screen 42

Truck Setup Screen

To change truck options, click on the box next to the option that needs to be changed and a
check mark should appear. After the box is checked or unchecked as needed, click on “SEND
Changes to Truck” and follow the prompts on the screen. Component hardware on the forklift
may need to be changed for the forklift to function correctly. Also on this screen are two tabs,
one for Vehicle Manager Software, and another for Display Manager/ Power Amp Software.
Click on the one needed and the Software Screen will appear. See Screen 43 & 44

37
 Screen 43

Vehicle Manager Software Screen

Screen 43 shows a Vehicle Manager Software screen. Highlight the software model number
and the different versions available will appear. Select the needed software version and then
click “Load VM with Selected Software Version” and follow the prompts on the screen.

38
 Screen 44

Display Manager/ Power Amp Software

Flashware is used to load the Display Card or the Traction & Lift Power Amps. On the Truck
Setup screen click on the “Display Manager/Power Amp Software” tab and Screen 44 will
appear. Highlight the needed software version and then click on “LOAD with selected
software version”. Follow the prompts on the screen to finish the procedure.

39
 8HBW23 Walkie and 8BWS10/13 Stacker
Flashware is used on the 8HBW23 and 8BWS10/13 to install Vehicle Manager Software in a
new ETAC card, re-install Vehicle Manager Software in an existing ETAC card, change Configure
settings, and perform diagnostics. The USB to CAN adapter and walkie cable are needed to
connect the laptop computer to the forklift. When Flashware is first connected to the truck,
the Truck Setup screen will appear. See Screen 45.

A new ETAC card is blank, with no software installed. The forklift will not operate and “test”
will show on the display. Flashware is used to download or install the Vehicle Manager
Software. If the ETAC card is blank, when Flashware is connected to the forklift the Software
screen will appear. See Screen 46.

Screen 45

Truck Setup Screen

40
 Screen 46

Vehicle
Manager

Truck Software Screen

Highlight the Vehicle Manager as the device and the box on the lower left will populate with
the software versions. Highlight the correct software version and click on the tab “Load
Device with Selected Software Version. See Screen 47. Follow the prompts on the screen to
finish loading the software. If it is a blank ETAC card, it is necessary install the serial number
and the date of manufacture (year only). On the Truck Setup Screen enter the forklift serial
number and click on “SEND Changes to the Truck”. Follow the prompts on the screen to finish
the process.

41
 Screen 47

“Load Device with

Selected Software
Version”

91560020.s37

42
 Screen 48

Diagnostics Screen

Flashware can also be used for diagnostics. Screen 48 shows the Diagnostic screen on an
8BWS13. The Traction Amplifier inputs and outputs are in the box on the left hand side and
are labeled. The jelly beans on the right hand side are the ETAC card inputs. The jelly beans
will light green when they are active. This also shows the lift potentiometer voltage.

43