Flexi AC 1200 2.0T Parts Manual

42055-00 Issue E

Flexi AC 1200 2.0TParts Manual

Flexi G4

2

A350-1A - Document Revision Details 2

3

A351-1A - Front Axle Assembly 4

6

9

A352-1A - Chassis Kit 10

12

13

14

16

17

18

19

A353-1A - Oil Tank Module 20

22

23

25

26

28

32

0 0

33

34

36

0 0

37

38

41

43

44

45

A355-2A - Wiring Looms 46

0

49

50

52

53

54

56

58

60

62

A356-6A - Narrow Aisle Hydraulic Components - Third Stage (TW) 65

67

69

0

0 0

0

0

1

Flexi G4

A356-3A-03 - Third Stage Assembly

A356-4A - Narrow Aisle Fork Carriage Assembly

A356-5A - Narrow Aisle Hydraulic Components - Fixed Stage (TW)

A356-7A - Narrow Aisle Hydraulic Components - Fixed Stage (NA)

A356-8A - Narrow Aisle Hydraulic Components - Third Stage (NA)

0

0

A356 - Mast System

A356-1A - Mast Support Assembly

A356-2A - Mast Assembly

A356-3A - Mast Fitting

A356-3A-01 - Fixed Stage Assembly

A356-3A-02 - Second Stage Assembly

A355-1B - Electrical Module - Zapi Traction

A355-1B-00 - AC3 Inverter Assembly

A355-1B-01 - Solenoid Switches

A355-1B-02 - Reverse Alarm Kit

A355-1B-03b - Cold Store Additions (Solenoid SW80A 24V)

0

A353-2A - Spool Valve Assembly

A353-3A-00 - Steering Cover and Dash

A354 - Brake System

A354-1A - Pedal Plate Module

A354-3A - Brake Backplate Assembly

A355 - Control System

A352-5A - Controls Assembly

A353 - Hydraulic System

A353-1A-00 - Lift Motor Module

A353-1A-01 - Lift Motor Module (Schabmuller)

A353-1A-02 - Steer Motor Module

A353-1A-03 - Steer Motor Module (Schabmuller)

0

A351-2A - Axle and Transmission Assembly

A352 - Chassis Fitting System

Contents

A350 - Revisions

A351 - Transmission System

A352-1A-00 - Steering Motor Extension

A352-1A-01 - Additional Chassis Parts

A532-2A - Seat and Covers

A352-3A - Overhead Guard

A352-4A - Battery Tray Assembly

Rev Date Revised By

A 14 / 03 / 2013 H Clemmet

B 05 / 06 / 2013 H Clemmet

C 12 / 07 / 2013 R Bennett

D 27 / 02 / 2014 P Burns

2

P Callan

Alternate Carriage reference numbers amended P Callan

Updated , mast details P Callan

Updated

P Callan

Document Revision Details (A350-1A)

Description Approved

First Issue

Revisions

3

Flexi G4

0

A351

TransmissionSystem

4

Flexi G4

Front Axle Assembly (A351-1A)

fig. A351-1A: Front Axle Assembly, Exploded View

Transmission System

Ref TW Pt No NA Pt.No Description Qty Notes

00 B350686 7661.09.000 Front Wheel Assembly 2 Contains reference parts 1 & 2

01 B350603 4978.15.000 Transmission Assembly 1 See A351-2A, page 6

1 0 7635.15.000 Tyre - Front 2 16.25 x 7 x 11.25 Black Treaded

1a 0 7635.24.000 Tyre - Front 2 16.25 x 7 x 11.25 Non Marking Treaded

2 30106C 41218.00 Hub 2

3 30114C 41288.02 Axle Support Fabrication 1

4 30107A - Hinge Pin 1 To join items 3 & 7

5 30108 - Washer 1 M8

6 30102B 41288.04.02 Crossbeam 1

7 30104C 41045.04 Front Counterweight 1

8 M0919-GE50ES 7644.01.000 Bearing 2

9 M1312-R75 6422.01.000 Circlip 2

10 M1401-M20*60 6121.20.060 Screw - Socket Cap Head 1 M20 x 60

11 M1602011 - Washer 1 M10

12 M1401-M20*70 6211.20.070 Bolt - Hex Head 1 M20 x 70

13 M1606-M20 6120.20.000 Washer - Spring 5 M20

14 M1321001 6566.04.000 Grease Nipple 2 M10




18 3002772 42380.00 Terminal Mounting Plate* 1

19 E0303031 55530.01.000 Terminal Block* 1

20 M1602-M6 6110.06.000 Washer - Flat* 2 M6

21 M1606-M6 6120.06.000 Washer - Spring* 2 M6

22 M1402-M6*16 6121.06.016 Screw - Cap Head* 2 M6 x 16

23 M1602005 6110.08.000 Washer - Flat 2 M8


25 M1424-M8*20 6121.08.020 Screw - Cap Head 2 M8 x 20

26 3004375 42330.00 Cable Protection plate 1



29 E2102008 55492.06.000 Traction Motor 1 AM243.0070

29a 0 55492.08.000 Traction Motor 1 Schabmuller TSA240-200-210

30 30114P03 - Axle Clamp 2




34 - 4978.15.005 Wheel Nut 12

35 - 42431 Back Door Spacer 1

36 - 55492.08.001 Encoder Sensor 1

5

Flexi G4

Transmission System

Front Axle Assembly (A351-1A)

Parts List

6

Flexi G4

Transmission System

Axle and Transmission Assembly (A351-2A)

fig. A351-2A: Axle and Transmission Assembly, Exploded View


00 B351440 4978.17.000 Transmission Assembly 1 Parts: All excluding 51

01B350605 - Differential Assembly 1 Parts: 10, 26, 27, 30, 31, 39, 40, 41, 54, 55 and 02

02 B350568 - Differential Case 1 Parts: 28, 29

1 35678 4978.17.006 Front Tyre Base Axle 1

2 35682 4978.17.004 Gear Casing 1

3 30088A 30088 + 30094 Spacer 2

4 M1308-10*32 4978.15.016 Key 1 10 x 8 x 32

5 30091A 30091 Cover Plate 2

6 M1424-M8*20 - Bolt 6 M8 x 20

7 M0909-30307 4978.15.002 Taper Roller Bearing 3 30307

8 30074 30074 Intermediate Gear 1

9 30073A 30073 Wheel-Helical 1


11 30093F 30093 Gear Casing 2 1

12 M1301-16*20 M1301.16*20 Pin 2 16 x 20

13 35677 4978.17.002 Connecting Shaft 1

14 M1301-16*40 M1301.16*40 Pin 4 16 x 40

15 35680 4978.17.001 Front Tyre Base Axle 1

16 M0702053 4978.15.001 O-ring 2 TB80 x 105 x 13 (ACM)

17 30085A 30085 Front Hub 2

18 30086 30086 Axle Screw 12

19 M0801-AS234 - O-Ring 2


21 M1422002 M1422.CBS5.8 Screw - Cap Head 6 CBS5-8

22 M1301-10*30 M1301.10*30 Pin 4 10 x 30

23 30083A 4978.15.013 Nut - Lock 2

24 30084A 4978.15.014 Nut - Lock 2

25 35681 4978.17.003 Front Axle-Long 1

26 M1424004 M1401.M10*30 Bolt - Hex Head 12

27 32098 31502017 Differential Gear 2

28 30082B 30082 Differential Case 1 M10 x P1-25 x 30

29 30081B 30081 Differential Case 1

30 32096 32502009 Washer - Flat 2

31 M1424-M8*65 M1402.M8*65 Bolt - Hex Head 12 M8 x 65

32 35679 4978.17.005 Front Axle-Short 1


34 30076A 4978.15.010 Input Pinion-Helical 1

35 30071 30071 Spacer 1

36 - - - - -

37 30075 30075 Helical Gear 1

38 31594 92502010 Breather 2

39 32104 32502015 Differential Gear 4

40 32102 32502014 Differential Washer 4

41 32100 30080 Differential Spider 1

42 M1424007 - Bolt 6

43 M0604008 92502010 Screw Plug 1 Breather

44 30296 4978.15.018 Washer 1

45 30297 - Washer 1

M1423008 6111.10.030 Bolt - Hex Head 7 M10 x 30

M1402-M10*25 6211.10.025 Bolt - Hex Head 1 M10 x 25

47 M0702052 4978.12.014 O-ring 1 Output shaft seal ø42 x ø72 x 8mm

48 M0604005 - Bung 2

49 M1424009 - Bolt 5

50 30087 4978.15.005 Nut - Wheel 12

51 E2102010 55492.07.000 Traction Motor 1 AC - 074 10kW

51a 0 55492.08.000 Traction Motor 1 Schabmuller TSA240-200-210

52 30094 4978.15.017 Shim 2

53 M1602-M10 6110.10.000 Washer - Flat 8 M10



56 0 55492.08.001 Encoder Sensor 1 Schabmuller

7

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Parts List

46

Transmission System

Axle and Transmission Assembly (A351-2A)

9

Flexi G4

A352

Chassis FittingSystem

0

10

Flexi G4

fig A352-1A: Chassis Kit, Exploded View

Chassis Fitting System

Chassis Kit (A352-1A)


00 - - Steering Motor Extension 1 See List A352-1A-00 p12

01 - - Additional Chassis Parts 1 See List A352-1A-01 p13

02 - 41386.02 Swivel Hose Bracket 1 See List A353-3A p27

1 34951H 41265.17 Chassis Fabrication 1 Pallet Truck Batt. Removal

1a - 41277.05 Stub Axle 2

1b - - Leg Guards 2

1c - - Step Plate 1

2 M1602028 6110.12.000 Washer - Flat 4 M12



5 30262B 41328.02 Quarter Ballast 1 Left Hand Side

6 34898 6453.01.000 Roll Pin 2

7 35940A 41328.01 Quarter Ballast 1 Right Hand Side



10 30372 7093.01.000 Brass Tee Piece 1



13 30373A 6581.03.000 Brake Pipe* 1 R/H Wheel to Tee

14 30374A 6581.04.000 Brake Pipe* 1 L/H Wheel to Tee

15 30375A 6581.05.000 Brake Pipe* 1 Tee to Brake Master Cylinder

16 M0609001 6517.02.000 Hole Insert 6 Side Ballast ø42mm

17 30250B 41345 Battery Plug Bracket 1



20 30260C 41320.02 Side Ballast 1 Left Hand Side

21 E3805010 55131.14.000 Fan 2 48 Volt

22 M1602-M4 6110.04.000 Washer - Flat 8 M4


24 30261C 41320.01 Side Ballast 1 Right Hand Side


26 3001163 - Anti-Slip Plate Left 1

27 3001167 - Anti-Slip Plate Right 1

28 30290 41318 Electrical Mounting Bracket 1

29 M1423-M10*30 6111.10.030 Bolt 2 M10 x 30


31 - 41286 Steer Motor Mounting Plate 1

32 - 4690.01.000 Pipe Clip (not shown) 2 1/4"

11

Flexi G4

Parts List





2 M1501-M12 6111.12.000 Nut - Plain 8 M12

3 30077E 41535.00 Steer Pinion Shaft 1

4 M0901-6210ZZ 7735.01.000 Bearing 2 6210-2RSI ø90 x ø20 x 50mm

5 30419B 41536.01 Bearing Housing 1 To suit Danfoss

6 0 41536 Bearing Housing 0 To suit Albroco

7 M1312-S50 6588.01.000 Circlip 1 M50

8 M0305006 4980.01.000 Hydraulic Steer Motor 1 Danfoss OMSW400

9 0 44000.02.000 Hydraulic Steer Motor 0 Albroco MLSH-E400 M2


11 35943 4975.06.000 Brass Straight Fitting 1 1/4" BSP - 8mm T

12 M0601016 4443.01.000 Connector - Male 2

13 M0801015 4520.01.000 Seal 2 1/2" BSP Dowty

12

Flexi G4

Parts List

Steering Motor Extension (A352-1A-00)

fig. A352-1A-00 - Steering Motor Extension, Exploded View



Additional Chassis Parts (A352-1A-01)

Ref NA Pt.No Description Qty Notes

1 41265.17 Chassis Fabrication 1 Pallet Trick Batt. Removal

2 41577.00 Battery Retaining Assembly 1

2a 41577.01 Battery Tank Fixed Support 1 Part of item 2

2b 41577.02 Mounting Bracket 1 Part of item 2

2c 41577.03 Retaining Latch 1 Part of item 2

3 6355.01.001 Split Pin 2 Battery Retainer

4 6120.10.000 Washer - Spring 2 M10

5 6121.10.025 Setscrew - Cap Head 2 M10 x 25

6 6120.08.000 Washer - Spring 4 M8

7 6111.08.025 Setscrew - Hex Head 2 M8 x 25

8 6110.08.000 Washer - Flat 4 M8

9 - Bolt - Button Head 4 M4 x 25

10 6110.04.000 Washer - Flat 4 M4

11 6120.04.000 Washer - Spring 5 M4

12 #REF! #REF! ####Right-Handed

Left Handed

13 7763.01.000 Extension Spring 2 12 O/D x 1-5 Wire x 35 F/L

14 41316.00 Nut - Dome Face 2 M10

15 6211.12.060 Bolt - Hex Head 2 M12 x 60

16 6110.12.000 Washer - Flat 8 M12

17a Handbrake Cable Linkage 1 Set Reference 41302-12

17b Handbrake Cable Linkage 1

17c Handbrake Cable Linkage 1

18 7626.10.000 Bush - Glacier 2 PM1215 DX

19 6111.12.000 Nut - Plain 2 M12

20 6120.12.000 Washer - Spring 6 M12

21 6111.04.000 Nut - Plain 4 M4

13

Flexi G4

41302.30



fig. A352-1A-01: Additional Chassis Parts, exploded view

Parts List

14

Flexi G4

fig. A352-2A: Seat & Covers, Exploded View


Seat and Covers (A352-2A)


1 41339-03 Battery Lid 1

2 41337-11 Front Electronics Cover 1

3 41390-00 Arm Rest Cushion 1

4 41385-00 Seat Pan 1

5 41336-08 Front Nose Cone Cover 1

6 7659.01.000 Gas Strut 1 650N

7 42046.00 Cable Protection Bracket 1 Protects Seat Switch Cable

8 55497.01.000 Document Holder 1

9 7633.27.000 Seat 1 MSG 20 inc- Belt (PVC)

10 41321.08 Floor Plate 1

11 6131.06.012 Bolt - Countersunk 4 M6 x 12

12 6221.08.030 Bolt - Cap Head 5 M8 x 30

13 6131.08.000 Nut - Nyloc 5 M8

14 7598.05.000 Latch 2 For Battery Lid

15 6110.10.000 Washer - Flat 4 M10

16 41372.11 Seat Frame 1

17 6211.10.040 Screw - Hex Head 4 M10 x 40

18 6610.01.000 Screw - Button Head 4 M5 x 12

19 4976.01.000 Nylon Pipe 1 8mm diameter ( /metre)

20 41394.00 Seat Stop 1

21 6600.01.000 Screw - Pozi Pan 2 M10 x 25 Taptite

22 6110.10.000 Washer - Flat 4 M10

23 7307.01.000 Edging Strip 1 ( /metre)

24 41342-00 Direction Lever Cover 1

25 6110.08.000 Washer - Flat 7 M8

26 - - - -

27 - - - -

28 6131.06.000 Nut - Nyloc 2 M6

29 6120.08.000 Washer - Spring 4 M8

30 7703.03.000 Rubber Buffer 2


32 6110.06.000 Washer - Flat 2 M6

33 6121.06.020 Screw - Cap Head 2

34 7633.27.005 Seat Runners 2

35 - Pipe Connector 1

36 41372.02 Seat Frame Support 3 0

37 7703.03.000 Seat Frame Buffer 3 0

38 41944.00 Hose Protection Funnel 1

39 - - - -

40 42350.00 Seat Latch 1 Includes 40a, Striker Plate

41 Seat Latch Striker Plate 0

42 Foot Horn Button -

43 0 Foot Horn Switch 0 -

44 - - - -

45 6121.05.010 Bolt - Dome Head 2

46 41394 Seat Stop Plate 1 0

47 - - - -

48 - - - -

49 6211.04.050 Bolt - Hex Head 4 M4 x 50

50 55131.14.000 Fan 1 48 Volt

15

Flexi G4


Seat and Covers (A352-2A)

Parts List

1D180416


1 41268.10 Overhead Guard 1

2 6171.14.045 Bolt - Durlock 8 M14 x 45 NA

3 6711.14.045 Bolt - High Tensile 0 M14 x 45 TW

4 - - - -

5 55421.15.000 Headlight 2 0

6 6211.08.030 Bolt - Hex Head 2 M8 x 30

7 6111.08.000 Nut - Plain 2

8 42272 Headlight Guard 2 0

96210.08.016 Bolt - Dome Head 4 M8

10 5676.14.000 Beacon 1 Also see 5676-10-000 (Beacon) and 5676-11-000 (Guard)

11 6211.06.020 Bolt - Hex Head 3 M6 x 20

12 6131.06.000 Nut - Nyloc 3

13 7404.02.000 Rear View Mirror 1 0

14 6151.05.010 Screw - xxx Head CSK 2 M5 x 10

16

fig. A352-3A: Overhead Guard, Exploded View

Parts List


Overhead Guard (A352-3A)

Flexi G4

Parts List


1 - 41369.07 Battery Tank 1

2 0 0 Battery Tank Foot 1 Part of Battery Tank

3 35664A 40366.03 Battery Connection Bracket 1

4 M1410-M6*12 6610.01.000 Bolt - Button Head 2 M6 x 12

5 - - - - -

6 E3801008 - Cell 24 5HPzS-775

7 - 55385.13.000 Battery Connection 1

8 M1401-M6*50 6221.06.050 Setscrew - Cap Head 4 M6 x 50

9 M1602-M6 6110.06.000 Washer - Flat 8 M6

10 M1501-M6 6131.06.000 Nut - Nyloc 4 M6

17


Battery Tray Assembly (A352-4A)

fig. A352-4A: Battery Tray Assembly

Flexi G4


55526.01.000 Key Barrel

55527.01.000 Base

55521.01.000 Contact Block

55521.02.000 Contact Block

2 5202.04.000 Direction Lever 1

3 7633.19.001 Seat Switch 1

4 41340.00 Spool Valve Lever Cover 1

5 6549.02.000 Jack Nut 4 M6

6 55519.02.000 Headlight Switch 1 55520-02-000 for switch base

7 61151.06.020 Bolt - Dome Head 4 M6 x 20

8 - Lift Lever Assembly 1 See List A353-2A

9 - Tilt Lever Assembly 1 See List A353-2A

10 - Sideshift Lever Assembly 1 See List A353-2A

11 7620.02.000 Handbrake Assembly 1 See List A353-2A

12 55498.01.000 Horn Switch 1

18

1


Controls Assembly (A352-5A)

fig. A352-5A: Controls Assembly

Parts List

1

19

0

A353

HydraulicSystem

Flexi G4

20

Hydraulic System

Oil Tank Module (A353-1A)

fig. A353-1A: Oil Tank Module, Exploded View

Flexi G4


1 30207C 41282.03 Oil Tank 1 Top profile - 41282-05

2 35661A 41282.01 Oil Tank Lid 1 Lift Motor

3 35662A 41282.04 Oil Tank Lid 1 Steer Motor

4 30206 41282.02 Gasket 2

5 E2102002 5454.05.000 Lift Pump Motor 1 Schabmuller TSL160-125 See A353-1A-00

6 3000816 4981.03.000 Steering Pump 1 WSP20-8D

7 E2102003 55309.04.000 Steering Pump Motor 1 Schabmuller TSL150-070 See A353-1A-01

8 3000815 44047.03.000 Lift Pump 1 WSP20-14S

9 30623 4004.01.000 Serrated Drive 2

10 M0303002 4634.01.000 Suction Filter - Steering 1

11 M0303003 4632.01.000 Suction Filter - Lift 1 1" BSP

12 M0303004 4959.01.000 Return Filter Assembly 1

13 30614 4994.03.000 Cast Flanged Elbow 3 1/2" BSP

14 30615 4994.01.000 Cast Flanged Elbow 1 3/4" BSP

15 35458 4489.01.000 Connector 1 1" BSP - 1/2" BSP M/M

16 M0601007 44038.17.000 Connector - Lift Suction 2 1 5/16" JIC - 3/4" BSPM

17 M0601008 44038.18.000 Connector - Lift Suction 1 1 5/16" JIC - 1" BSPM

18 M0601009 44038.16.000 Connector - Lift/Steer Pressure 2 1 1/16" JIC - 1/2" BSPM

19 M0601010 44038.16.000 Connector - Steer Suction 2 1 1/16" JIC - 1/2" BSPM

20 35467 4487.04.000 Connector - Three-Way Fitting 1 1/2" BSPM - 1/2" BSPF - 3/8" BSPM

21 35895 4460.01.000 Connector - Bulkhead 1

22 M0507002 4976.01.000 Nylon Pipe 1 8mm diameter (/metre)

23 M1613006 4524.01.000 O-ring 1 1" BSP Dowty

24 35470 4693.01.000 Connector - Lift Pressure 1

25 30344A 42453.02 Hose - Steer Pump Suction 1 20 dia. Tube + Sleaves + Nuts

26 30345 42453.04 Hose - Lift Pump Suction 1 25 dia. Tube + Sleaves + Nuts

27 31790A 42453.01 Steel Tube - Steer Pressure 1 18 dia. Tube + Sleaves + Nuts

28 35735A 42453.03 Steel Tube - Lift Pressure 1 20 dia. Tube + Sleaves + Nuts

29 34818 3729.43 Oil Pipe - Tank Return 1 3/8" BSP


31 M1424-M8*25 6121.08.025 Screw - Socket Head 4 M8 x 25

32 M1613005 4520.01.000 O-ring 1 1/2" BSP Dowty

33 M1423-M6*20 6111.06.020 Setscrew 12 M6 x 20



36 M0303005 4959.02.000 Return Filter 1

37 - 4959.03.000 Breather Filter 1

38 M0303006 4959.12.000 Gasket 1

39 35988 4693.02.000 Connector - Steer Pressure 1

40 34115 5454.05.001 Carbon Brush Set 8

41 34505 55309.04.001 Carbon Brush Set 4

42 M1613004 4523.01.000 O-ring 3 3/4" BSP Dowty

43 - 5882.01.000 Rubber Terminal Boot 4

44 - - Nut 2 As part of items 6 and 8

45 M0203014 4975.01.000 Male Stud Elbow Fitting 2 1/4" BSP - 8mm elbow

21

Hydraulic System


Parts List

Flexi G4


1 - 55294.04.001 Drive Endhead 1 H95-003A

2 - 55294.04.002 Bearing 1 BR-107

3 - 55294.04.003 Drive End Bearing Circlip 1 H-014

4 - 55294.04.004 Fan 1 A90-109C

5 - 5454.02.003 Armature & Fan Assembly 1 BM5-3006

6

7

8 - 5454.04.000 Brush Spring 8 B89-016

9 - 5454.02.007 Brush 8 A89-012A

10 - 55295.03.007 Brush Plate Assembly 1 J89-1064

11 - 5454.02.005 Brush Lead Assembly Kit 1 L91-2035S

12 - 55294.04.008 Bearing 1 BR-205

13 - 55294.04.009 Washer - Wavy 1 H-016

14 - 5454.02.001 Commutator Endhead 1 L97-002C

15 - 5454.02.006 Headband Assembly 1 HB-1052

16 - 5454.02.000 Lift Motor Complete 1

16a - 5454.02.000S Lift Motor Complete 1 Service Exchange

22

- 5454.02.004 Field Coil Kit 1 BM5-3005S

Lift Motor Module (A352-1A-00)

fig. A353-1A-00: Lift Motor Module, Exploded View

Parts List

Hydraulic System


Flexi G4


1 - 55294.01.001 Drive Endhead 1 H95-003A

2 - 55294.04.002 Bearing 1 BR-107

3 - 55294.04.003 Drive End Bearing Circlip 1 H-014

4 - 55294.04.004 Fan 1 A90-109C

5 - 55309.02.001 Armature & Fan Assembly 1 BM5-3146

6 - 55309.02.002 Field Coil Kit 1 BM5-3005AS

7 - 55309.02.003 Brush 4 A97-1012

8 - 5454.04.000 Brush Spring 4 B89-016

9 - 55309.02.004 Brush Plate Assembly 1 A88-1064

10 - 55294.04.007 Brush Lead Assembly Kit 1 L93-2035AS

11 - 55294.04.008 Bearing 1 BR-205

12 - 55294.04.009 Washer - Wavy 1 H-016

13 - 55309.02.005 Commutator Endhead 1 G97-102A

14 - 55309.02.006 Headband Assembly 1 HB-1061

15 - 55309.02.000 Steer Motor Complete 1

15b - 55309.02.000S Steer Motor Complete 1 Service Exchange

23


Steer Motor Module (A353-1A-01)

fig. A353-1A-01: Steer Motor Module, Exploded View

Parts List

Hydraulic System

Flexi G4

24

Flexi G4

Hydraulic System

Spool Valve Assembly (A353-2A)

fig. A353-2A: Spool Valve Assembly, Exploded View


1 4977.08.000 Spool Valve 1

2 41317 Spool Valve Mounting Bracket 1

3 7620.02.000 Handbrake Assembly 1

4 4970.03.000 Flow Regulator 2

5 4667.01.000 Hold Valve 1 48V

6 5277.01.000 Spool Valve Micro Switch 1

55219.02.000 1

55219.03.000 1

8 7668.01.000 Handbrake Cable 1

9 41348.08 Lever 1 1 Side-shift

10 41348.07 Lever 2 1 Tilt

11 41348.06 Lever 3 1 Lift

12 7638.07.000 Lever Knobs 1 Side-shift

13 7638.06.000 Lever Knobs 1 Tilt

14 7638.05.000 Lever Knobs 1 Lift

15 41391 Retaining Strap 1

16 41393 Bolt - Hex Head 1 Handbrake

17 6121.10.035 Screw - Cap Head 1 M10 x 35 (cut down)

18 6221.10.020 Screw - Cap Head 1 M10 x 20

19 4813.01.000 Connector 2 1/4" - 3/8" BSP M/M

20 6601.01.000 Screw - Cap Head 4 M4 x 25 Taptite

21 4437.01.000 Blanking Plug 1 1/2" BSP

22 4520.01.000 O-ring 4 1/2" Dowty

23 4441.02.000 Coupler M0601021 4 1/2" - 1/2" BSP M/M

24 4459.02.000 Spacer 2

25 3729.14 Rubber Hose 1 1/2"

26 3729.139 Rubber Hose 1 1/2"

27 3729.113 Rubber Hose 1 1/2" Mast

28 3729.51 Rubber Hose 1 1/2" Hold Valve

29 3729.119 Rubber Hose 1 1/4" Tilt Forward

30 3729.134 Rubber Hose 1 1/4" Side Shift Right

31 3729.12 Rubber Hose 1 1/4" Tilt Back

32 3729.135 Rubber Hose 1 1/4" Side Shift Left

33 3729.6 Rubber Hose 1 1/4" Tilt Regulator

34 3729.61 Rubber Hose 1 1/4" Side Shift Regulator

35 6221.08.055 Screw - Cap Head 3 M8 x 55

36 6120.08.000 Washer - Spring 3 M8

37 6111.06.040 Screw - Cap Head 2 M6 x 40

38 #REF! #REF! ####

39 #REF! #REF! #### #REF!

40 #REF! #REF! #### #REF!

41 #REF! #REF! #### #REF!

42 #REF! #REF! #### #REF!

43 #REF! #REF! #### #REF!

44 - Spacer 1

45 - Washer - Flat 1 Part of Item #42

46 6110.10.000 Washer - Flat 2 M10

47 6120.10.000 Washer - Spring 2 M10

48 6111.10.030 Bolt - Hex Head 2 M10 x 30

49 6120.03.000 Washer - Spring 2 M3

50 4977.08.016 Spool Valve Lever Housing 3

25

Flexi G4

Hydraulic System

Spool Valve Assembly (A353-2A)

Parts List

7 Limit Switch Body XCM-A1022

26

Flexi G4

Hydraulic System

Steering Column Module (A353-3A)

fig. A353-3A: Steering Column Module, Exploded View


00 - Steering Assembly 1 Contains Items; 6 - 10

01 - Steering Cover & Dash 1 Contains Items; 18, 36, 51, 58-61 & 63-65

1 - - - -

2 - - - -

3 - - - -

4 6138.14.000 Nut 1 M14 x 1.5

5 7647.11.000 Steering Wheel 1 ø 13" TW 2 Spoke

6 7647.10.000 Steering Wheel 1

7 7646.06.000 Steering Column 1 To suit 7

7a 7646.03.000 Steering Column 1 To suit 7a

8 - Steering Wheel Cover 1 As part of Item # 7

8a - Label 1 See A357-1A

9 6120.10.000 Washer - Spring 10 M10

10 41285.02 Steering Column Support 1 0

11 6110.12.000 Washer - Flat 1 M12

12 41365 Hinge Screw 2

13 6110.12.000 Washer - Flat 2 M12

14 6111.10.030 Bolt - Hex Head 2 M10 x 30

15 7601.01.000 Adjustable Hand Lever 1 Locking Lever

16 55481.01.003 Zapi Display Unit 1 Panel Kit

17 4443.01.000 Connector 4 1/2" BSP - 3/8" BSP M/M

18 4520.01.000 O-ring 4 1/2" BSP Dowty

19 3729.146 Rubber Hose 1 Orbital / Lock Valve

20 3729.145 Rubber Hose 1 Orbital / Lock Valve

21 3729.143 Rubber Hose 1 Pump / Orbital

22 3729.144 Rubber Hose 1 Orbital / Tank Filter

23 3729.142 Rubber Hose 1 Lock Valve / Steer Motor

24 3729.141 Rubber Hose 1 Lock Valve / Steer Motor

25 44001.09.000 Steer Orbital Valve 1 100cc

26 41242.09 Steering Column Mount 1 0


28 4472.01.000 Connector 2

29 4522.01.000 O-ring 5 3/8" BSP Dowty

30 4973.01.000 Steering Lock Valve 1 0

31 6110.08.000 Washer - Flat 2 M8

32 6121.08.090 Screw - Cap Head 2

33 #REF! #REF! #### #REF!

34 #REF! #REF! #### #REF!

35 (3729.108) Rubber Hose 1 Lock Valve / Tank

36 - - - -

37 5400.01.000 Resistor 2 RS 131.788 Paired with Item #50

38 4521.01.000 O-ring 3 1/4" BSP Dowty

39 - Steel Tube 2

40 5300.02.000 Horn 1 48V

41 41386.02 Swivel Hose Bracket Assembly 1 Mounting Bracket

42 41386.03 Swivel Hose Bracket Assembly 1 Lower Swivel Bracket Part of 41

43 41386.04 Swivel Hose Bracket Assembly 1 Upper Swivel Bracket Part of 41

44 6121.10.100 Screw - Cap Head 2 M10 x 100

45 6131.10.000 Nut - Nyloc 2 M10

46 6131.12.000 Nut - Nyloc 1 M12

47 4915.01.000 Pressure Test Point 1 1/4" BSP

48 4914.03.000 Adjustable Elbow 2 3/8" BSP - 3/8" BSP

49 7307.01.000 Edging Strip 2 (/metre)

50 5400.01.000 Diode 1 RS 183.4466 Paired with Item #37

51 55498.02.000 Hill Start Switch 1

52 - - -

53 - Knob Steering Wheel 1 As part of Item # 7

54 7804.01.002 Signal Conditioning Module 1

55 42379.00 Rubber Clamp Pipe 1

56 6211.05.014 Bolt - Hex Head 2 M5 x 14 (Modify )

57 7804.01.001 Steering Sensor 1

58 55508.06.000 Red LED Indicators 2

59 55508.07.000 Yellow LED Indicators 2

60 42315.00 Dashboard Fascia 1

61 41338.05 Steering Cowl 1 Zapi MIDI only

62 #REF! #REF! #### #REF!

63 #REF! #REF! #### #REF!

64 #REF! #REF! ####

65 #REF! #REF! #### #REF!

66 #REF! #REF! #### #REF!

67 #REF! #REF! #### #REF!

27

Flexi G4

Hydraulic System


Parts List


1 55508.07.000 Yellow LED Indicator 2

2 55508.06.000 Red LED Indicator 2

3 55481.01.003 Electronic Display 1

4 6121.08.035 Screw - Cap Head 4 M8 x 35

5 7598.04.000 Handle 2

6 55498.02.000 Hill Start Switch 1

7 42026 Sticker 1

8 41338.05 Steering Cowl 1

9 42315 Dashboard Fascia 1

28

Hydraulic System


Steering Cover & Dash (A353-3A-00)

fig. A353-3A-00: Steering Column Module - Steering Cover & Dash

Parts List

29

Flexi G4

0

A354

Brake System


1 41297.04 Pedal Mounting Plate 1

2 55481.01.001 Accelerator Pedal Unit 1 Part of Traction Panel Kit

3 55215.03.000 Accelerator Potentiometer 1

4 55215.02.000 Accelerator Rubber 1

5 41296.03 Brake Pedal 1

6 55215.07.000 Brake Pedal Rubber 1

7 41291.01 Brake Push Rod 1

8 7197.07.000 Brake Master Cylinder 1 0.7"

9 CA829802 Micro Switch 1

10 7081.01.000 Expansion Spring 1

11 41297.1 Cable Guard 1

12 7625.01.000 Bush - Glacier 2 0

13 6121.06.012 Screw - Cap Head 2 M6 x 12

14 6121.08.025 Screw - Cap Head 2 M8 x 25

15 6221.08.035 Screw - Cap Head 1 M8 x 35

16 6110.08.000 Washer - Flat 3 M8

17 6131.08.000 Nut - Nyloc 4 M8

18 6111.10.020 Screw - Setscrew 2 M10 x 20

19 6120.10.000 Washer - Spring 2 M10

20 6221.12.030 Screw - Cap Head 1 M12 x 30

21 6211.12.090 Bolt - Hex Head 1 M12 x 90

22 6111.12.000 Nut - Plain 1 M12

23 6131.12.000 Nut - Nyloc 1 M12

30

Flexi G4

Brake System

Pedal Plate Module (A354-1A)

fig. A354-1A: Pedal Plate Module, Exploded View

Parts List


00 7738.11.000 Brake Back Plate Assembly 1 Lefthand; See A354-3A

00 7738.10.000 Brake Back Plate Assembly 1 Righthand; See A354-3A

01 - Hub Rear Assembly 1

1 7738.08.000 Brake Cable 2

2 7738.08.002 Clip 2

3 6566.05.000 Grease Nipple 2 M6

4 6171.14.040 Bolt - Durlock 12 M14 x 40

4a 6171.14.050 Bolt - Durlock 12 M14 x 50 Repair Axle

5 4998.01.000 O-ring 2 ø75 x ø105 x 13mm

6 7624.01.000 Taper Roller Bearing 2 32013

7 41278.00 Rear Hub 2 6"

8 0 0 0 0

9 7624.02.000 Taper Roller Bearing 2 32010 50 x 80 x 20

10 4998.06.000 Nut - Lock 2 M45 x 1-5mm

11 4998.07.000 Washer - Lock 2

12 41293 Grease Cover 2 0

13 6120.06.000 Washer - Spring 12 M6

14 6121.06.012Screw - Button Head

12 M6 x 12

15 6131.06.012 Screw - Csk Socket Head 6 M6 x 12

31

Flexi G4

Brake System

Rear Wheel Assembly (A354-2A)

fig. A354-2A: Rear Wheel Assembly, Exploded View

Parts List

Brake Backplate Assembly (A354-3A)


1 7738.10.000 Brake Backplate R/H 1

1 7738.11.000 Brake Backplate L/H 1

2 7738.12.000 Adjuster 2 Manual

3 7738.07.001 Cylinder - Wheel 2

4 - Common Shoe * 2

5 7738.07.005 Tension Spring 4

6 7738.07.006 Tension Spring 2

7 7738.07.007 Spring 4

8 - Lefthand Shoe * 1

8 - Righthand Shoe * 1

9 7738.07.010 Bracket Spring 4

10 - Fixed Slice 4

11 6111.06.016 Bolt - Hex Head 4 M6 x 16

12 6120.06.000 Washer - Spring 4 M6

13 7738.07.008 Bleed Nipple 2


15 7738.07.012 Nordlock Washer 2 M12

* - 7738.07.009 Brake Shoe Kit 1 Includes:

2 x No-4 - Common Shoe

1 x No-8 - Left Hand Shoe

1 x No-8 - Right Hand Shoe

32

Flexi G4

fig. A354-3A: Brake Backplate Assembly, Exploded View

Parts List

Brake System

33

Flexi G4

A355

Control System

0

34

Flexi G4

Control System

Electrical Module - Zapi Traction (A355-1B)

fig. A355-1B-1: Electrical Module - Zapi Traction

35

Flexi G4

Control System


fig. A355-1B-2: Electrical Module - Zapi Traction Components


00 - Zapi Controller Assembly 1

1 41283.03 Backplate 1

2 6211.06.030 Bolt - Hex Head 6 M6 x 30

3 6120.06.000 Washer - Spring 10 M6

4 6110.06.000 Washer - Flat 10 M6

5 55522.02.002 Traction Controller 1 AC3 Truck Serial No Required

6 55327.01.000 Audiable Alarm 1 Reverse Horn

7 6211.06.016 Bolt - Hex Head 10 M6 x 16

8 - Contactor Mounting Bracket 1

9 6211.05.012 Bolt - Hex Head 2 M5 x 12

10 C5188.04 Terminal Block 1


12 55522.02.005 Negative Terminal Post 1


14 6120.04.000 Washer - Spring 2 M4

15 6110.04.000 Washer - Flat 2 M4

16 55370.10.000 Relay Holder Blue 2

17 6211.03.030 Bolt - Hex Head 4 M3 x 30

18 6111.03.000 Nut 4 M3

19 5849.02.000 11-pin Relay 2 48V

20 55370.09.000 Timer Relay 2

21 - Fuse Holder 3


23 55097.04.000 Fuse 1 5A

24 55201.01.000 Fuse 2 10A

25 - Fuse Holder Mounting Bracket 1

26 - Washer - Flat 2

27 55490.02.000 K4 Contactor 1 SW200-421 48V

28 55490.06.000 K6 Contactor 1 SW200-261 48V

29 - Contactor Mounting Bracket 1


31 55427.03.000 Load Resistor 1 120Ω 50W

32 55444.07.000 Fuse Holder 3

33 - Fuse Mounting Plate 1

34 55096.01.000 Fuse 2 400A

35 5367.01.000 Fuse 1 100A

36 55490.01.000 K5 Contactor 1 SW80B-10 48V

37 - Cable Line 1 1 K4 to Fuse



40 - Cable Line 4 1 Fuse to Traction Contactor

41 - Cable Line 5 1 Traction Contactor to Negative Post

42 55450.01.000 Temperature Switch 1

43 6211.03.010 Bolt - Hex Head 4 M3 x 10

44 - K5 Label 1

45 - K4 Label 1

46 - K6 Label 1

47 - K9 Label 1

48 - K10 Label 1

49 6120.08.000 Washer - Spring 5 M8

50 6111.08.000 Nut 3 M8

51 6110.08.000 Washer - Flat 11 M8

52 6110.08.000 Washer - Flat 5 M8

53 6210.10.030 Bolt - Hex Head 1 M10 x 30

54 6111.10.000 Nut 3 M10

55 42090.01 Cable Line 6 1


57a - 48V Pin 1

55385.20.000 Battery Plug Female 1 Female Plug / Male Pins

57b - 55385.21.000 Battery Plug Male 1 Male Plug / Female Pins

55385.14.000 Battery Plug Handle 1

36

Flexi G4

Control System


Parts List

Solenoid Switches (A355-1B-00)


K4 Contactor - SW200-421 - Bypass / Hydraulic Lift Contact

1 55490.02.000 K4 Complete 1 Includes Items 2 - 12

2 - Top Cover 1

3 - Fixing Screws 2

4 - Contact Fixtures 2 See Item #12

5 - Return Spring 1 See Item #12

6 - Fixed Contact 2 See Item #12

7 - Moving Contact 1 See Item #12

8 - Top Cover Base 1

9 - Plunger 1 See Item #12

10 - Coil & Magnet 1

11 - End Cap 1

12 55490.02.100 Contact Tip Kit 1 Includes; 4, 5, 6, 7, 9

K5 Contactor - SW80B-10 - Steer Contact

13 55490.01.000 K5 Complete 1 Includes Items 14 - 21

14 - Top Cover 1

15 - Fixing Screws 2

16 - Contact Fixtures 2

17 - Return Spring 1 See Item #21

18 - Fixed Contact 2 See Item #21

19 - Moving Contact 1 See Item #21

20 - Coil & Magnet 1 See Item #21

21 55490.01.100 Contact Tip Kit 1 Includes; 17, 18, 19, 20

K6 Contactor - SW200-261 - Steer Contact

As K4, except:

1 55490.06.000 K6 Complete 1

12 55490.06.100 Contact Tip Kit 1

37

Flexi G4

Parts List

Control System


fig. A355-1B-00: Solenoid Switches K4 & K6 fig. A355-1B-00: Solenoid Switch K5

Reverse Alarm Kit (A355-1B-01)


1 - 55327.01.000 Audible Alarm 1

2 - - Cables 2

3 - 6607.01.000 Screw - Taptite 2 M4 x 6 Taptite

4 - 6621.01.000 Washer - Flat 2

5 - 6111.03.000 Nut - Plain 4 M3

38

Flexi G4

fig. A355-1B-01: Reverse Alarm Kit

Parts List

Control System


Cold Store Additions (Electrical) (A355-1B-02)


1 - 55197.06.000 Fuse Terminal 1

2 - 55201.01.000 Fuse 10A 1

3 - 55415.01.000 Resistor 33Ω 100W 3

4 - 55209.01.000 Resistor 100Ω 50W 2

5 - 55427.09.000 Resistor 150Ω 25W 3

6 - 55468.02.000 Thermostat 1 RS159-2099

7 - 55490.01.000 SW80 Solenoid Switch 1 48V

8 - 55115.01.000 Suppressor 1

Cold Store Additions (Solenoid SW80) (A355-1B-02b)


00 - 55490.01.000 SW80 Complete 1 48V

1 - - Top Cover 1

2 - - Fixing Screws 2

3 - - Contact Fixtures 2 See Item #9

4 - - Return Spring 1 See Item #9

5 - - Fixed Contact 2 See Item #9

6 - - Moving Contact 1 See Item #9

7 - - Coil & Magnet 1

8 - 5618.01.000 Auxiliary Terminal Block 1 See Item #9

9 - 55490.01.100 Contact Tip Kit 1 Includes; 3, 4, 5, 6, 8

39

Flexi G4

fig. A355-1B-02b: Cold Store Additions - Solenoid SW80; Exploded View

Parts List

Control System


Parts List

40

Flexi G4

Control System

Wiring Looms (A355-2A)

fig. A355-2A: Truck Wiring Looms


1 - 42035.00 Main Wire Loom - Truck 1

2 - 41883.01 Wire Loom 1 Short H / B Switch Loom

3 - 41883.02 Wire Loom 1 Short Spool M / Switch Loom

4 - 41323.03 Wire Loom 1 To Lift / Tilt and Steer Motors

5 - 42035.31 Wire Loom 1 Hillstart Push Button

6 - 42082.00 Wire Loom - Panel 0 Included on Panel (not shown)

7 - 41323.05 Heavy Cable No2 1 Line Contactor - Fuse

8 - 41323.06 Heavy Cable No20 1 Steer & Lift / Tilt Motor Link

9 - 41323.07 Heavy Cable No20 1 Steer Motor - Main

10 - 41323.08 Heavy Cable P2 1 Lift / Tilt Motor - K4

11 - 41323.09 Heavy Cable P4 1 Steer Motor - K5

12 - 42342.15 Traction Motor Cable 1



15 - - - - -

16 - - - - -

17 - 41883.17 Wire Loom (Keycode Switch) 1 To Keyswitch & Horn

18 - 41323.18 Optional Wire Loom 1 Keycode System

19 - 41323.20 Wire Loom 2 Fan Lead

20 - 41323.21 Wire Loom 1 Horn Push Button

21 - 41323.22 Wire Loom 1 Horn

22 - 41323.23 Wire Loom 1 Reverse Alarm

23 - 55523.01.007 Encoder Harness 1 CFR Motor

24 - 41883.25 Wire Loom 1 Fwd / Rev Lever

25 - 41323.26 Wire Loom 1 Battery Cable - Panel / Male

26 - 41323.27 Wire Loom 1 Battery Cable - F / F

41

Flexi G4

Wiring Looms (A355-2A)

Parts List

Control System

42

Flexi G4

43

Flexi G4

A356

Mast System

0

44

Flexi G4

Mast System

Mast Support Assembly (A356-1A)

fig. A356-1A: Mast Support Assembly, Exploded View


1 41249.05 Mast Support Fabrication 1

2 41424.01 Slewing Ring 1

3 6711.12.075 Set Pin - Hex Head 47 M12 x 75 Grade 10-9

4 41249.26 Mast Support Clamp 2 Right, part of item #1

5 6221.20.090 Screw - Cap Head 4 M20 x 90

6 6120.20.000 Washer - Spring 4 M20

7 6566.04.000 Grease Nipple 2 M10

8 7626.01.000 Bush - Glacier 2 Mast

9 41343.01 Mast Retaining Washer 2

10 6120.10.000 Washer - Spring 2 M10

11 6121.10.030 Screw - Cap Head 2 M10 x 30



14 - - -

15 6591.01.000 Spring Clip 4

16 6110.24.000 Washer - Flat 4 M24

17 44030.10.000 Cylinder - Tilt 2

18 44130.10.000 Cylinder - Tilt 2

19 3526.03 Tilt Cylinder Mounting Shaft 4 0

20 4415.01.000 Connector 4

21 44012.04.000 0 0 9/16" - 1/4" BSPM

22 - Spindle 1 0

23 4521.01.000 O-ring 8 1/4" BSP Dowty

24 6211.14.065 Bolt - Hex Head 2 M14 x 65 TW

25 6121.08.025 Bolt - Cap Head 2 M8 x 25 TW

26 6111.14.000 Nut 2 M14 TW

27 7627.01.000 Thrust Washer 2 Glacier TW

28 4914.04.000 Connector 90 2 1/4" BSP - 1/4" BSP Elbow

29 44012.05.000 0 0

30 4415.01.000 Connector 2 1/4" BSP - 1/4" BSP M/M

31 4439.01.000 Blanking Plug 2 1/4" BSP

32 41249.24 Bearing Seat 1 Part of item #1

33 41249.21 Articulation Shaft 1 0

34 6120.16.000 Washer - Spring 4 M16

35 6210.16.055 Screw - Button Head 4

36 41249.25 Mast Support Clamp 1

45

Flexi G4

Mast System

Mast Support Assembly (A356-1A)

Parts List


30772A 3912mm

30773A 4521mm

31190 4800mm

30774A 4928mm

3157D 5550mm

30770A 6600mm

30771A 7410mm

30158 8400mm

30778A 3912mm

30779A 4521mm

31191 4800mm

30780A 4928mm

30173 5550mm

30776 6600mm

30777 7410mm

30159 8400mm

30184A 3912mm

30785A 4521mm

31192 4800mm

30786A 4928mm

30185 5550mm

30782 6600mm

30783 7410mm

30160 8400mm

46

Flexi G4

Mast System

Mast Assembly (A356-2A)

3 -

2

Mast Sub-Assembly Third

Stage

(Inner)

Parts List

1 -

Mast Sub-Assembly Fixed

Stage

(Outer)

1

fig. A356-2A: Mast Assembly, Exploded View

-

Mast Sub-Assembly Second

Stage

(Middle)

1

1


B350615 3912mm

B350618 4050mm

B350607 4200mm

B350616 4521mm

B351030 4620mm

B350608 4800mm

B350617 4928mm

B351025 5010mm

B351391 5220mm

B351031 5400mm

B350606 5550mm

B350622 6000mm

B351026 6210mm

B350609 6600mm

B351027 7020mm

B351028 7200mm

B350610 7410mm

B350611 7620mm

B351029 8010mm

B350620 8204mm

B350612 8220mm

B350613 8400mm

B350614 8610mm

B351032 8820mm

B350621 9000mm

47

Flexi G4

fig. A356-3A: Mast Fitting - Full Assembly, Exploded View

Parts List

00 Full Mast Assembly 1-

Mast System

Mast Fitting (A356-3A)

Fixed Stage Assembly (A356-3A-01)

Ref UK Pt.No Description Qty Notes

1 - Washer - Flat n M10 2t

2 7629.05.000 Rubber Buffer 2 40mm

3 6110.10.000 Washer - Flat 2 M10

4 6121.10.040 Screw - Cap Head 2 M10 x 40

5 6131.10.000 Nut - Nyloc 4 M10

48

Flexi G4

Mast System


fig. A356-3A-01: Mast Fitting - Fixed Stage, Exploded View

Parts List

Fixed Stage Assembly (A356-3A-01)


6 41410.00 Cylinder Clamp 2 0

7 6121.10.045 Screw - Cap Head 4 0

4200mm

5010mm

5550mm

6000mm

6600mm

7020mm

7620mm

8010mm

8610mm

9000mm

9 6353.01.000 Split Pin 4 0

10 7694.03.000 Chain Anchor Pin 2 8234-09

11 7694.02.000 Chain Anchor Bolt 2 BL0534 MB1

12 6111.16.000 Nut - Plain 2 M16

13 6131.16.000 Nut - Nyloc 2 M16

14 40558.06 Limit Switch Bracket 1 0

55219.02.000 Limit Switch 1 0

55219.03.000 0.00 1 0

16 6121.04.016 Screw - Cap Head 2 M4 x 16

17 6120.06.000 Washer - Spring 2 M6


19 41451.11 Bulkhead Bracket 1 0

20 6120.06.000 Washer - Spring 2 M6

4200mm

5010mm

5550mm

6000mm

6600mm

7020mm

7620mm

8010mm

8610mm

9000mm

22 6566.05.000 Grease Nipple 2 M6

23 4143.00 Manifold 1 0

24 6120.08.000 Washer - Spring 2 M8

25 6121.08.020 Screw - Cap Head 2 M8 x 20

6596.01.000 Shim Standard 40 ID x 0-5

6596.03.000 0.00 Heavy Duty

7671.01.000 Roller Assembly Standard

7773.01.000 0.00 Heavy Duty

28 6161.10.010 Grubscrew 2 M10 x 10

29 - - - -

30 41396.xx Fixed Stage Mast Fabrication 1 [Mast No.]

4200 04

5010 08

5550 01

6000 13

6600 16

7020 18

7620 21

8010 23

8610 26

9000 28

49

Flexi G4

4

Cylinder - Main Lift

(Fixed Stage)

27

.XX

n

Mast System


2

26

Leaf Chain

- To Third Stage Mast, Lower

8

21

For UK Masts replace .XX

LIFT HEIGHT

41410

15

Parts List (cont-)

41404.xx

2

Second Stage Assembly (A356-3A-02)

50

Flexi G4

Mast System


fig. A356-3A-02: Mast Fitting - Second Stage, Exploded View

Second Stage Assembly (A356-3A-02)


6596.01.000 Standard 40 ID x 0-5

6596.03.000 Heavy Duty

7671.01.000 Standard

7773.01.000 Heavy Duty

3 40558.03 Reaction Block 1 0

4 6131.06.025 Setscrew - Countersunk 2 M6 x 25

5 6150.30.000 Washer - Flat 2 M30 Light

6 40149 Hose Pulley 2 0

7 40206 Bearing Spacer 3 0

8 40148.01 Chain Pulley 2 0

9 7672.01.000 Pulley Bearing 2 6306-2RS

10 6428.01.000 Circlip 2 72mm Internal

11 3169.35.000 Spacer 1 0

12 41408.01 Hose Pulley 1 0


14 41409 Pulley Shaft 1 2 30 OD x 112

15 6120.08.000 Washer - Spring 2 M8

16 6111.08.016 Setscrew 2 M8 x 16

17 [Mast No.] Second Stage Mast Fabrication 1 #REF!

51

Flexi G4

Shim n

2 4


Roller Assembly

Parts List

1

Mast System

Third Stage Assembly (A356-3A-03)


1 - Washer - Flat n M10 2t

2 7629.06.000 Rubber Buffer 2 25mm

3 6110.10.000 Washer - Flat 2 M10

4 6121.10.035 Screw - Cap Head 2 M10 x 35

5 6111.10.016 Screw - Cap Head 2 M10 x 16

6 6120.10.000 Washer - Spring 2 M10

7 41409.01 Pulley Shaft 2 2 0

52

Flexi G4

Mast System

Parts List


fig. A356-3A-03: Mast Fitting - Third Stage, Exploded View

Third Stage Assembly (A356-3A-03)


4200mm

5010mm

5550mm

6000mm

6600mm

7020mm

7620mm

8010mm

8610mm

9000mm

9 6353.01.000 Split Pin 8 0

10 7694.03.000 Chain Anchor Pin 4 8234-09

11 7694.02.000 Chain Anchor Bolt 4 BL0534 MB1

12 6111.16.000 Nut - Plain 4 M16

13 6131.16.000 Nut - Nyloc 4 M16


15 41407 Chain Pulley 2 0

16 7672.01.000 Pulley Bearing 2 6306-2RS

17 6428.01.000 Circlip 2 72mm Internal

18 40206.02 Bearing Spacer 2 0

19 41408 Hose Pulley 2 0

20 6120.08.000 Washer - Spring 2 M8

21 6111.08.016 Setscrew 2 M8 x 16

4200mm

5010mm

5550mm

6000mm

6600mm

7020mm

7620mm

8010mm

8610mm

9000mm

23 6161.08.010 Grubscrew 2 M8 x 10

24 41406 Pulley Yoke 2 0

25 6161.08.020 Grubscrew 4 M8 x 20

6596.01.000 n Standard 40 ID x 0-5

6596.03.000 0 Heavy Duty

7671.01.000 4 Standard

7773.01.000 0 Heavy Duty

28 41410.01 Cylinder Clamp 2 0

29 6131.08.000 Nut - Nyloc 4 M8


31 [Mast No.] Third Stage Mast Fabrication 1 #REF!

53

Mast System

Leaf Chain

Parts List (cont-)

8

7694.01.000

(length as required)

Roller Assembly

Cylinder - Free Lift

(Third Stage)2

26

0

2


27

Shim

22

Flexi G4


1 41411.xx Side-Shift 1 Bolzoni 860mm

7671.01.000 Roller Assembly 4 Standard

7773.01.000 0.00 0 Heavy Duty

3 7694.02.000 Chain Anchor Bolt 2 BL 0534 MB1

4 7694.03.000 Chain Anchor Pin 2 8234-09

5 6111.16.000 Nut - Plain 2 M16

6 6131.16.000 Nut - Nyloc 2 M16

7 6353.01.000 Split Pin 2 0

6596.01.000 Shim n Standard 40 ID x 0-5

6596.03.000 0.00 0 Heavy Duty

9 41692.01 Fork 2 950 x 125 x 40mm

10 41692.02 Fork 2 1150 x 125 x 40mm

11 6566.06.000 Grease Nipple - Angled 4 M6 45˚

12 6121.16.025 Screw - Cap Head 1 M16 x 25

13 6121.08.012 Screw - Cap Head 1 M8 x 12

14 6120.08.000 Washer - Spring 1 M8

15 6121.12.030 Screw - Cap Head 2 M12 x 30

16 4997.21.005 Upper Wear Pad - Right 1 0

17 4997.21.004 Upper Wear Pad - Left 1 0

18 4997.21.002 Lower Wear Pad - Right 1 0

19 #REF! #REF! #### #REF!

54

8

Mast System

Narrow Aisle Fork Carriage Assembly (A356-4A)

Parts List

2

fig. A356-4A: Bolzoni Fork Carriage Assembly, Exploded View

Flexi G4

Alternative Fork Carriage Assembly (A356-4A-00)


1 #REF! #REF! #### #REF!

2 #REF! #REF! 1 #REF!











13 #REF! #REF! #REF!

13a #REF! #REF! #REF!






7671.01.000 Roller Assembly Standard

7773.01.000 0.00 Heavy Duty


55

Parts List

4

4

Mast System

19

Narrow Aisle Fork Carriage Assembly (A356-4A)

fig. A356-4A-00: Kaup Fork Carriage Assembly, Exploded View

Flexi G4


#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!

#REF!#REF!

56

Narrow Aisle Hydraulic Components - Fixed Stage (A356-5A)

fig. A356-5A: Narrow Aisle Hydraulic Components - Fixed Stage, Exploded View

Parts List

1

Mast System

#REF! #####REF!

Important:- All masts are stamped either UK or TW, please state when ordering parts.- For all masts stamped with TW, please see item number 33, page 58.- If in doubt supply MA number - stamped by mast pigot.

Flexi G4


9/16 JIC - 9/16 JIC

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

9/16 JIC - 9/16 JIC

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

9/16 JIC - 9/16 JIC

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

57

1

4

3 Main Lift Feed Pipe

141522.xx Side-Shift Feed Pipe

Parts List (cont-)

2 Main Lift Feed Pipe 1

Mast System


0

0

Flexi G4


9/16 JIC - 9/16 JIC

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

6 Manifold 1 1/2" BSP - 3/8" BSP

7 4971.05.000 Safety Valve 1 1/2" BSP 40L

8 - Blanking Plug 1 1/2" BSP Socket

9 4627.04.000 Pipe Clamp 3 8mm Twin

10 44057.12.000 Connector - Male 2 1/2" BSP - 7/8 JIC

11 44057.13.000 Bulkhead Coupling 1 1/2" BSP - 7/8 JIC

12 44057.14.000 Connector - Male 4 3/4 SAE UNF - 9/16 JIC

13 44057.15.000 Connector 2 1/4 BSP - 9/16 JIC

1/2" BSP

0.00

0.00

0.00

1/4" BSP

0.00

0.00

0.00

16 41451.11 Bulkhead Bracket 1 0.00

17 4627.05.000 Pipe Clamp 4 15mm Single

18 6111.08.020 Setscrew 2 M8 x 20


20 6111.06.016 Bolt - Hex Head 2 M6 x 16

21 6120.08.000 Washer - Spring 2 M8

22 4245.03.000 Rupture Valve - Set to 1-6mm 2 3/4" UNF

23 6120.06.000 Washer - Spring 2 M6

24 - Main Lift Adapter 0 3/8" BSP - 9/16 JIC

25 - Main Lift Connector 0 1/2" BSP - 1/2" BSP

26 - O-ring 0 1/2" BSP Dowty

27 41437.00 O-ring 0 3/8" BSP Dowty

0 - 0.00 0 0.00

0 - 0.00 0 0.00

0 - 0.00 0 0.00

0 - 0.00 0 0.00

0 - 0.00 0 0.00

0 0.00 0.00 0.00 0

0.00

0.00 0.00 0

0.00 0.00 0

0.00 0.00 0

0.00 0.00 0

0.00 0.00 0

0.00 0.00 0

0.00 0.00 0

0.00 0.00 0

0.00 0.00 0

0.00 0.00 0

0.00 0.00 0

0.00 0.00 0

58

0

41452.xx

15 41453.xxSide-Shift Rubber Hose

Assembly2

14Free Lift Rubber Hose

Assembly1

0.00 0.00

Mast System

5 41524.xx Side-Shift Feed Pipe


1

0.00

Parts List (cont-)

0 0.00 0.00

0.000

Flexi G4

59

Flexi G4

Narrow Aisle Hydraulic Components - Third Stage (A356-6A)

fig. A356-6A: Narrow Aisle Hydraulic Components - Third Stage, Exploded View

Mast System


1/4" BSP Hose

0.00

0.00

0.00

1/4" BSP Hose

0.00

0.00

0.00

1/4" BSP Hose

0.00

0.00

0.00

1/4" BSP Hose

0.00

0.00

0.00

5 C Bulkhead Coupling 3 1/4" BSPM

6 - Nut - Lock 4 0.00

1/2" BSP Hose

0.00

0.00

0.00

8 4487.05.000 Feed Pipe 1 1/2" BSP - 3/8" BSP - 3/8" BSP

9 M0501087 Rubber Hose 1 3/8" BSP Hose


11 44012.03.000 Bulkhead Coupling 2 3/4 SAE - 3/8" BSPM

12 44012.12.000 Connector - Elbow 3 M14X1.5 - 1/4" BSPM


14 44057.64.000 Connector - T 1 1/4" BSP - 8mm T

15 42312 Pipe 1 8mm Tube

16 44012.13.000 Connector - Elbow 3 1/4"BSPM Bulkhead

17 4690.03.000 Pipe Clamp 2 8mm

18 - Nut 1 0.00

19 4521.01.000 O-ring 2 1/4" BSP Dowty

20 - - - -

21 - - - -

22 6111.06.012 Bolt - Hex Head 2 M6 x 12

23 6120.06.000 Washer - Spring 2 M6

60

Flexi G4

7 Rubber Hose 1

4 Side-Shift Hose - Primary 241453.xx

41452.xx

3 Side-Shift Hose - Secondary 2

2 Side-shift Feed Pipe 141488.xx

41454.xx

1 Side-shift Feed Pipe 141487.xx

Parts List

Narrow Aisle Hydraulic Components - Third Stage (A356-6A)

Mast System

61

Flexi G4

A357

Accessory System

0

62

Flexi G4

fig. A357-1A-2: Label Locations 1

Accessory System

Labels (A357-1A)

fig. A357-1A-1: Labels


0 0 0 0 0.00

0 40084 Warning Label 1 General Operation

0 40084 Warning Label 2 Hand Crush _ Side force

0 40084 Warning Label 2 Foot Crush - Side Force

0 40084 Warning Label 1 Tip Over

0 40084 Warning Label 2 Overhead Loads

0 41344 Warning Label 1 Seat lift

0 41431 Warning Label 1 Battery Retainers

0 0 0 0 0.00

0 40084 Instruction Label 2 Lifting Points

0 40113 Instruction Label 1 Pedal functions

0 40129 Instruction Label 1 Transmission Oil Fill Point

0 40129 Instruction Label 1 Hydraulic Oil Fill Point

0 40155 Instruction Label 1 Battery Charge Level

0 7207.01.00 Instruction Label 1 Lifting Points

0 41579 Instruction Label 4 Horn Symbol

0 41930 Instruction Label 1 Light Symbol

0 42026 Instruction Label 1 Hill-start Symbol

0 40085 Instruction Label 1 Battery Charge Label

0 1234 Instruction Label 0 Fwd-n-Rev

0 42168 Instruction Label 0 Tyre

0 41431 Instruction Label 0 Qualified Personel

0 41579 Instruction Label 0 Horn - Foot

63

Flexi G4

Accessory System

Labels (A357-1A)

Parts List


41404.200 GKN

41404.300 Tail Lift

41404.400 Rangers

41405.200 GKN

41405.300 Tail Lift

41405.400 Rangers

44030.14.001 TW

44030.04.002 NA

#REF! Standard

4997.21.010 Cold Store

5 - 4997.44.017 Seal Kit - Sideshift Cylinder(for Alt Carriage Assembly)2 Seal Kit A Kaup

6 - 4977.03.000 Seal Kit - Spool Valve Assebly 1 Seal Kit


1 - 41249.22 Axel Pivot Shaft 1

2 - 3526.05 Tilt Cylinder Mounting Shaft 4

3 - - Cold Store Grease a/r Shell Alvania RA

4 - - Transmission Oil 0.8 Litre, Aral Degol PAS150

5 - - Hydraulic Oil 50 Litres, Mobil Aero HFACastrol Hyspin AWH-1-5

6 - 55413.03.000 Low Temperature 4 Core 6m Igus CF9.10.04

7 - 41715.03 Traction Motor 1

8 - 7801.01.000 Air Sentry 1

9 - 7801.02.000 Air Sentry Adaptors 2 MP Filtri No. A-103

10 - TB194 Technical Bulletin ref 0

11 0 41409.05 Pulley Shaft - 2nd Stage 0

64

4 B350802 Seal Kit - Sideshift Cylinder 1

Cold Store Additions (Mechanical) (A357-2A)

Parts List

2 B350739 Seal Kit - Free Lift Cylinder 2

3 B350740 Seal Kit - Tilt Cylinder 2

Seal Kit (A357-2A)

Parts List

1 B350738 Seal Kit - Main Lift Cylinder 2

Accessory System

Flexi AC 1200 2.0T Parts Manual

Documents

Transcript of Flexi AC 1200 2.0T Parts Manual