Flexi G4 Parts Manual - Narrow Aisle Inc

42055-00 Is

Flexi G4Parts Manual

2A350-1A - Document Revision Details 2

3A351-1A - Front Axle Assembly 4

6

9A352-1A - Chassis Kit 10

121314161718

19A353-1A - Oil Tank Module 20

2223242628

29A354-1A - Pedal Plate Module 30

3132

33A355-1B - Electrical Module - Zapi Traction 34

3738393940

43A356-1A - Mast Support Assembly 44

464748505254555659

61A357-1A - Labels 62

6464

65A358-1A - By Part Name i

xiiixxiii

Flexi G4

Contents

A350 - Revisions

A351 - Transmission System

A352-1A-00 - Steering Motor ExtensionA352-1A-01 - Additional Chassis Parts

A532-2A - Seat and CoversA352-3A - Overhead GuardA352-4A - Battery Tray Assembly

A358 - Index

A351-2A - Axle and Transmission Assembly

A352 - Chassis Fitting System

A352-5A - Controls Assembly

A353 - Hydraulic System

A353-1A-00 - Lift Motor ModuleA353-1A-01 - Steer Motor Module

A353-2A - Spool Valve AssemblyA353-3A - Steering Column Module

A353-3A-00 - Steering Cover and Dash

A354 - Brake System

A354-2A - Rear Wheel AssemblyA354-3A - Brake Backplate Assembly

A355 - Control System

A355-1B-00 - Solenoid SwitchesA355-1B-01 - Reverse Alarm KitA355-1B-02 - Cold Store Additions (Electrical)A355-1B-02b - Cold Store Additions (Solenoid SW80A 24V)

A355-2A - Wiring Looms

A356 - Mast System

A356-2A - Mast AssemblyA356-3A - Mast Fitting

A356-3A-01 - Fixed Stage AssemblyA356-3A-02 - Second Stage AssemblyA356-3A-03 - Third Stage Assembly

A356-4A - Narrow Aisle Fork Carriage AssemblyA356-4A-00 - Alternative Fork Carriage Assembly

A356-5A - Narrow Aisle Hydraulic Components - Fixed StageA356-6A - Narrow Aisle Hydraulic Components - Third Stage

A357 - Accessory System

A357-2A - Seal KitA357-3A - Cold Store Additions (Mechanical)

A358-2A - By Part Reference Number - NAA358-3A - By Part Reference Number - TW

Rev Date Revised By

A 14 / 03 / 2013 H ClemmetB 05 / 06 / 2013 H ClemmetC 12 / 07 / 2013 R BennettD

2

Revisions

P Ca

Document Revision Details (A350-1A)

Description Appro

First IssueAlternate Carriage reference numbers amended P CaUpdated , mast details P Ca

Flexi G4

Transmission System

A351-1A - Front Axle Assembly ………………………………………. p4A351-2A - Axle and Transmission Assembly .……………….………. p6

A351

TransmissionSystem

4

Transmission System

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 & 201 B350603 4978.15.000 Transmission Assembly 1 See A351-2A, page 61 M1211080 7635.14.000 Tyre - Front 2 16.25 x 7 x 11.25 Plain Black2 30106C 41218.00 Hub 23 30114C 41288.02 Axle Support Fabrication 14 30107A - Pin 1 To join items 3 & 75 30108 - Washer 1 M86 30102B 41288.04.02 Crossbeam 17 30104C 41045.04 Front Counterweight 18 M0919-GE50ES 7644.01.000 Bearing 29 M1312-R75 6422.01.000 Circlip 2

10 M1401-M20*60 6121.20.060 Screw - Socket Cap Head 1 M20 x 6011 M1602011 - Washer 1 M1012 M1401-M20*70 6211.20.070 Bolt - Hex Head 1 M20 x 7013 M1606-M20 6120.20.000 Washer - Spring 5 M2014 M1321001 6566.04.000 Grease Nipple 2 M1015 M1606-M24 6120.24.000 Washer - Spring 1 M2416 M1402-M20*140 6211.20.140 Bolt - Hex Head 4 M20 x 14017 M1423009 6121.20.060 Screw - Cap Head 2 M20 x 6018 3002772 42380.00 Terminal Mounting Plate 119 E0303031 55530.01.000 Terminal Block 120 M1602-M6 6110.06.000 Washer - Flat 2 M621 M1606-M6 6120.06.000 Washer - Spring 2 M622 M1402-M6*16 6121.06.016 Screw - Cap Head 2 M6 x 1623 M1602005 6110.08.000 Washer - Flat 2 M824 M1606-M8 6120.08.000 Washer - Spring 2 M825 M1424-M8*20 6121.08.020 Screw - Cap Head 2 M8 x 2026 3004375 42330.00 Cable Protection plate 127 M1606-M10 6120.10.000 Washer - Spring 3 M1028 M1423-M10*20 6121.10.020 Screw - Cap Head 2 M10 x 2029 55492-08-000 Traction Motor 1 AC Schabmueller30 30114P03 - Axle Clamp 231 M1401-M10*20 6121.10.020 Screw - Cap Head 1 M10 x 2032 M1606-M8 6120.08.000 Washer - Spring 1 M833 M1401-M8*20 6121.08.020 Screw - Cap Head 1 M8 x 2034 - 4978.15.005 Wheel Nut 12

Flexi G4

Transmission System

Front Axle Assembly (A351-1A)

Parts List

6

Axle and Transmission Assembly (A351-2A)

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

Transmission System


00 B350603 4978.15.000 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, 291 30095B 300095 Front Tyre Base Axle 12 30092E 30092 Gear Casing 13 30088A 30088 + 30094 Spacer 24 M1328-10*32 M1308.10*32 Key 1 10 x 8 x 325 30091A 30091 Cover Plate 26 M1424-M8*20 - Bolt 6 M8 x 207 M0909-30307 4978.15.002 Taper Roller Bearing 3 303078 30074 30074 Intermediate Gear 19 30073A 30073 Wheel-Helical 1

10 M0909-32013 7624.01.000 Taper Roller Bearing 6 3201311 30093F 30093 Gear Casing 2 112 M1301-16*20 M1301.16*20 Pin 2 16 x 2013 30090B 30090 Connecting Shaft 114 M1301-16*40 M1301.16*40 Pin 4 16 x 4015 30089A 30089 Front Tyre Base Axle 116 M0702053 4978.15.001 O-ring 2 TB80 x 105 x 13 (ACM)17 30085A 30085 Front Hub 218 30086 30086 Axle Screw 1219 M0801-AS234 - O-Ring 220 M1401-M10*30 6121.10.030 Screw - Cap Head 16 M10 x 3021 M1422002 M1422.CBS5.8 Screw - Cap Head 6 CBS5-822 M1301-10*30 M1301.10*30 Pin 4 10 x 3023 30083A 30083 Nut - Lock 224 30084A 30084 Nut - Lock 225 30079B 30079 Front Axle-Long 126 M1424004 M1401.M10*30 Bolt - Hex Head 1227 32098 31502017 Differential Gear 228 30082B 30082 Differential Case 1 M10 x P1-25 x 3029 30081B 30081 Differential Case 130 32096 32502009 Washer - Flat 231 M1424-M8*65 M1402.M8*65 Bolt - Hex Head 12 M8 x 6532 30078B 30078 Front Axle-Short 133 M0909-32009 4978.15.004 Taper Roller Bearing 1 3200934 30076A 4978.15.010 Input Pinion-Helical 135 30071 30071 Spacer 136 - - - - -37 30075 30075 Helical Gear 138 31594 92502010 Breather 239 32104 32502015 Differential Gear 440 32102 32502014 Differential Washer 441 32100 30080 Differential Spider 142 M1424007 - Bolt 643 M0604008 92502010 Screw Plug 1 Breather44 30296 4978.15.018 Washer 145 30297 - Washer 1

M1423008 6111.10.030 Bolt - Hex Head 7 M10 x 30M1402-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 8mm48 M0604005 - Bung 249 M1424009 - Bolt 550 30087 4978.15.005 Nut - Wheel 1251 55492-08-000 Traction Motor 1 AC Schabmueller52 30094 4978.15.017 Shim 253 M1602-M10 6110.10.000 Washer - Flat 8 M1054 M1605-M10 6120.10.000 Washer - Spring 39 M1055 M1605-M8 6120.08.000 Washer - Spring 18 M8

Flexi G4

Axle and Transmission Assembly (A351-2A)

Parts List

46

A352

Chassis FittingSystem

A352-1A - Chassis Kit ..................................................................... p10 A352-1A-00 - Steering Motor Extension ............................... p12 A352-1A-01 - Additional Chassis Parts ................................. p13A352-2A - Seat and Covers ............................................................ p14A352-3A - Overhead Guard ............................................................ p16A352-4A - Battery Tray Assembly ................................................... p17A352-5A - Controls Assembly ......................................................... p18

Flexi G4

10

Chassis Fitting System

Chassis Kit (A352-1A)

fig A352-1A: Chassis Kit, Exploded View


00 - - Steering Motor Extension 1 See List A352-1A-101 - - Additional Chassis Parts 1 See List A352-1A-202 - 41386.02 Swivel Hose Bracket 1 See List A353-3A1 34951H 41265.17 Chassis Fabrication 1 Pallet Trick Batt. Removal

1a - 41277.05 Stub Axle 21b - - Leg Guards 21c 34946 - Step Plate 1

42181.01 1 Left-hand42181.02 1 Right-hand

2 M1602028 6110.12.000 Washer - Flat 4 M123 M1605-M12 6120.12.000 Washer - Spring 6 M124 M1424-M12*40 6211.12.040 Bolt - Hex Head 8 M12 x 405 30262B 41328.02 Quarter Ballast 1 Left Hand Side6 34898 6453.01.000 Roll Pin 27 30263C 41328.01 Quarter Ballast 1 Right Hand Side8 M1606-M20 6120.20.000 Washer - Spring 10 M209 M1401-M20*50 6121.20.050 Screw - Cap Head 2 M20 x 50

10 30372 7093.01.000 Brass Tee Piece 111 M1606-M6 6120.06.000 Washer - Spring 4 M612 M1401-M6*40 6121.06.040 Screw - Cap Head 1 M6 x 4013 30373A 6581.03.000 Brake Pipe 1 R/H Wheel to Tee14 30374A 6581.04.000 Brake Pipe 1 L/H Wheel to Tee15 30375A 6581.05.000 Brake Pipe 1 Tee to Brake Master Cylinder16 3005090 6517.02.000 Hole Insert 6 Side Ballast ø42mm17 30250B 41345 Battery Plug Bracket 118 M1602-M8 6120.08.000 Washer - Spring 4 M819 M1401-M8*25 6121.08.025 Screw - Cap Head 8 M8 x 2520 30260C 41320.02 Side Ballast 1 Left Hand Side21 E3805003 55131.14.000 Fan 2 48 Volt22 M1602-M4 6110.04.000 Washer - Flat 8 M423 M1401-M4*45 6121.04.045 Screw - Cap Head 8 M4 x 4524 30261C 41320.01 Side Ballast 1 Right Hand Side25 M1401-M20*70 6121.20.070 Screw - Cap Head 8 M20 x 7026 3001163 - Anti-Slip Plate Left 127 3001167 - Anti-Slip Plate Right 128 30290 41318 Electrical Mounting Bracket 129 M1423-M10*30 6111.10.030 Bolt 2 M10 x 3030 M1606-M10 6120.10.000 Washer - Spring 2 M1031 - 41286 Steer Motor Mounting Plate 132 - 4690.01.000 Pipe Clip (not shown) 2 1/4"



Parts List

1d - Lower Step Plate

Flexi G4


1 M1401-M12*40 6121.12.040 Screw - Cap Head 8 M12 x 402 M1501-M12 6111.12.000 Nut - Plain 8 M123 30077F 41535.00 Steer Pinion Shaft 14 M0901-6210ZZ 7735.01.000 Bearing 2 6210-2RSI ø90 x ø20 x 50mm5 30419B 41536.01 Bearing Housing 1 To suit Danfoss6 M1312-S50 6588.01.000 Circlip 1 M507 M0305006 4980.01.000 Hydraulic Steer Motor 1 Danfoss OMSW4008 M1606-M12 6120.12.000 Washer - Spring 8 M129 35943 4975.06.000 Brass Straight Fitting 1 1/4" BSP - 8mm T

10 35455 4443.01.000 Connector - Male 2 1/2" - 3/8" BSP (to Steer Lock Valve)11 M0801015 4520.01.000 Seal 2 1/2" BSP Dowty12 35894 - Tee Connector 113 M0511001 4976.01.000 Nylon Pipe 2 Steer Motor Extension Bleed (/metre)

12



Steering Motor Extension (A352-1A-00)

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

Parts List

Additional Chassis Parts (A352-1A-01)

Ref NA Pt.No Description Qty Notes

1 41265.17 Chassis Fabrication 1 Pallet Trick Batt. Removal2 41577.00 Battery Retaining Assembly 1

2a 41577.01 Battery Tank Fixed Support 1 Part of item 22b 41577.02 Buckle Board 1 Part of item 22c 41577.03 Pin 1 Part of item 23 - Split Pin 2 Battery Retainer4 6120.10.000 Washer - Spring 2 M105 6121.10.025 Setscrew - Cap Head 2 M10 x 256 6120.08.000 Washer - Spring 4 M87 6111.08.025 Setscrew - Hex Head 2 M8 x 258 6110.08.000 Washer - Flat 4 M89 - Bolt - Button Head 4 M4 x 25

10 6110.04.000 Washer - Flat 4 M411 6120.04.000 Washer - Spring 5 M4

1242032.0242032.03

Battery Lid Bracket11

Right-HandedLeft Handed

13 7763.01.000 Extension Spring 2 12 O/D x 1-5 Wire x 35 F/L14 41316.00 Nut - Dome Face 2 M1015 6211.12.060 Bolt - Hex Head 2 M12 x 6016 6110.12.000 Washer - Flat 8 M1217a Handbrake Cable Linkage 1 Set Reference 41302-1217b Handbrake Cable Linkage 117c Handbrake Cable Linkage 118 7626.10.000 Bush - Glacier 2 PM1215 DX19 6111.12.000 Nut - Plain 2 M1220 6120.12.000 Washer - Spring 6 M1221 6111.04.000 Nut - Plain 4 M4

41302.30

Parts List



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

Flexi G4

14


Seat and Covers (A352-2A)

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


1 41339.01 Battery Lid 12 41337.10 Front Electronics Cover 13 41390.00 Arm Rest Cushion 14 41385.00 Seat Pan 15 41336.03 Front Nose Cone Cover 16 7659.01.000 Gas Strut 1 650N7 42046.00 Seat Wire Plate 1 Protects Seat Switch Cable8 55497.01.000 Document Holder 19 7633.27.000 Seat 1 MSG 20 inc- Belt (PVC)

10 41321.06 Floor Plate 111 6131.06.012 Bolt - Countersunk 4 M6 x 1212 6221.08.030 Bolt - Cap Head 5 M8 x 3013 6131.08.000 Nut - Nyloc 5 M814 7598.05.000 Latch 2 For Battery Lid15 6110.10.000 Washer - Flat 4 M1016 41372.00 Seat Frame 117 6121.10.040 Screw - Cap Head 4 M10 x 4018 6610.01.000 Screw - Button Head 4 M5 x 1219 4976.01.000 Nylon Pipe 1 8mm diameter ( /metre)20 41394.00 Seat Stop 121 6600.01.000 Screw - Pozi Pan 2 M10 x 25 Taptite22 6110.10.000 Washer - Flat 4 M1023 7307.01.000 Edging Strip 1 ( /metre) 24 41342.00 Direction Lever Cover 125 6110.08.000 Washer - Flat 7 M826 - - - -27 - - - -28 6131.06.000 Nut - Nyloc 2 M629 6120.08.000 Washer - Spring 4 M830 41372.02 Rubber Buffer 331 7703.03.000 Rubber Buffer 332 6110.06.000 Washer - Flat 2 M633 6121.06.020 Screw - Cap Head 234 7633.27.005 Seat Runners 235 - Pipe Connector 136 - Seat Frame Support 1 Contains 1 x #30 & 1 x #3137 - Seat Frame Buffer 1 Contains 1 x #30 & 1 x #3138 41944.00 Hose Protection Funnel 139 - - - -40 42350.00 Seat Latch 1 Includes 40a, Striker Plate41 - - - -42 - - - -43 - - - -44 6121.05.010 Bolt - Dome Head 2 M5 x 1045 41394.00 Seat Stop Plate 146 - - - -47 - - - -48 6211.04.050 Bolt - Hex Head 4 M4 x 5049 55131.14.000 Fan 2 48 Volt50 6112.04.000 Nut - Plain 4 M4

Flexi G4


Seat and Covers (A352-2A)

Parts List


1 41268.10 Overhead Guard 12 6171.14.045 Bolt - Durlock 8 M14 x 453 6120.14.000 Washer - Spring 8 M144 5306.06.000 Headlight 2 24V, 48V5 0 0 2 M8 x 306 6111.08.000 Nut - Plain 2 M87 42272.00 Headlight Guard 28 6210.08.016 Bolt - Dome Head 4 M8

95676.14.000 Beacon 1 Also see 5676-10-000 (Beacon) and 5676-11-000 (Guard)

10 6211.06.020 Bolt - Hex Head 3 M6 x 2011 6131.06.000 Nut - Nyloc 3 M612 7404.03.000 Rear View Mirror 113 6121.05.010 Screw - Cap Head 2 M5 x 1014 6110.05.000 Washer - Flat 1 M5

16


Overhead Guard (A352-3A)

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

Parts List

Parts List


1 34948 41369.30 Battery Tank 12 30418 - Support Leg 1 Part of 41369-103 35664 40366.03 Battery Connection Bracket 14 M1410-M6*12 6610.01.000 Bolt - Button Head 2 M6 x 125 M1503-M6 6111.06.000 Nut - Plain 2 M66 E3801008 - Cell 24 5HPzS-7757 - 55385.13.000 Battery Connection 18 M1401-M6*50 6221.06.050 Setscrew - Cap Head 4 M6 x 509 M1602-M6 6110.06.000 Washer - Flat 8 M6

10 M1501-M6 6131.06.000 Nut - Nyloc 4 M6

Flexi G4


Battery Tray Assembly (A352-4A)

fig. A352-4A: Battery Tray Assembly


- Ignition Switch55523.01.005 Key Barrel

2 5202.04.000 Direction Lever 13 7633.19.001 Seat Switch 14 41340.00 Spool Valve Lever Cover 15 6549.01.000 Jack Nut 4 M46 55519.02.000 Headlight Switch 1 55520-02-000 for switch base7 6111.06.020 Bolt - Hex Head 4 M6 x 208 - Lift Lever Assembly 1 See List A353-2A9 - Tilt Lever Assembly 1 See List A353-2A

10 - Sideshift Lever Assembly 1 See List A353-2A11 7620.02.000 Handbrake Assembly 1 See List A353-2A12 55498.01.000 Horn Switch 1

18


Controls Assembly (A352-5A)

fig. A352-5A: Controls Assembly

Parts List

1 1

Flexi G4

A353

HydraulicSystem

A353-1A - Oil Tank Module……………………………………..……. p20 A353-1A-00 - Lift Motor Module ……………………………... p22 A353-1A-01 - Steer Motor Module ....................................... p23A353-2A - Spool Valve Assembly……………………………………. p24A353-3A - Steering Column………………………………………….. p26 A353-3A-00 - Steering Cover & Dash ...…………………..... p28

20

Hydraulic System

Oil Tank Module (A353-1A)

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


1 30207C 41282.03 Oil Tank 1 Top profile - 41282-052 30211E 41282.01 Oil Tank Lid 1 Lift Motor3 30212D 41282.04 Oil Tank Lid 1 Steer Motor4 30206 41282.02 Gasket 25 E2102002 5454.02.000 Lift Pump Motor 1 See A353-1A-016 3000816 4981.03.000 Steering Pump 1 PLP20-8D7 E2102003 55309.02.000 Steering Pump Motor 1 See A353-1A-028 3000815 44047.03.000 Lift Pump 1 PLP20-14S9 30623 4004.01.000 Serrated Drive 2

10 M0303002 4634.01.000 Suction Filter - Steering 111 M0303003 4632.01.000 Suction Filter - Lift 1 1" BSP12 M0303004 4959.01.000 Return Filter Assembly 113 30614 4994.03.000 Cast Flanged Elbow 3 1/2" BSP14 30615 4994.01.000 Cast Flanged Elbow 1 3/4" BSP15 35458 4489.01.000 Connector 1 1" BSP - 1/2" BSP M/M16 34177 4409.01.000 Connector - Male 2 3/4" BSP - -3/4" BSP M/M17 M0601010 4466.01.000 Connector - Male 1 1" BSP - 3/4" BSP M/M18 M0601021 4441.01.000 Connector - Male 2 1/2" BSP - 1/2" BSP M/M19 33828 4452.01.000 Connector - Male 2 3/4" BSP - 1/2" BSP M/M20 35467 4487.02.000 Connector - Three-Way Fitting 1 1/2" M - 1/2" F - 3/8" M+G2209 BSP21 35471 - Connector 122 M0507002 4976.01.000 Nylon Pipe 1 8mm diameter (/metre)23 M1613006 4524.01.000 O-ring 1 1" BSP Dowty24 3001119 - Connector 125 30344A 3729.46 Hose 1 Steer Pump Suction26 30345 3729.47 Hose 1 Lift Pump Suction27 31790A 3729.44 Steel Tube 1 Steer Pump Pressure28 31791B 3729.45 Steel Tube 1 Lift Pump Pressure29 M0505001 3729.43 Oil Pipe 1 Steer Motor Bleed30 M1401-M8*35 6221.08.035 Screw - Cap Head 16 M8 x 3531 M1424-M8*25 6121.08.025 Screw - Socket Head 4 M8 x 2532 M1613005 4520.01.000 O-ring 1 1/2" BSP Dowty33 M1423-M6*20 6111.06.020 Setscrew 12 M6 x 20

34 M1606-M8 6120.08.000 Washer - Spring 20 M835 M1606-M6 6120.06.000 Washer - Spring 12 M636 M0303005 4959.02.000 Return Filter 137 - 4959.03.000 Breather Filter 138 M0303006 4959.12.000 Gasket 139 35988 - Connector 140 34115 5454.02.007 Carbon Brush 841 34505 55309.02.003 Carbon Brush 442 M1613004 4523.01.000 O-ring 3 3/4" BSP Dowty43 - 5882.01.000 Rubber Terminal Boot 444 - - Nut 2 As part of items 6 and 845 M0203014 4975.01.000 Male Stud Elbow Fitting 2 1/4" BSP - 8mm elbow

Flexi G4

Hydraulic System


Parts List


1 - 55294.04.001 Drive Endhead 1 H95-003A2 - 55294.04.002 Bearing 1 BR-1073 - 55294.04.003 Drive End Bearing Circlip 1 H-0144 - 55294.04.004 Fan 1 A90-109C5 - 5454.02.003 Armature & Fan Assembly 1 BM5-3006678 - 5454.04.000 Brush Spring 8 B89-0169 - 5454.02.007 Brush 8 A89-012A

10 - 55295.03.007 Brush Plate Assembly 1 J89-106411 - 5454.02.005 Brush Lead Assembly Kit 1 L91-2035S12 - 55294.04.008 Bearing 1 BR-20513 - 55294.04.009 Washer - Wavy 1 H-01614 - 5454.02.001 Commutator Endhead 1 L97-002C15 - 5454.02.006 Headband Assembly 1 HB-105216 - 5454.02.000 Lift Motor Complete 116a - 5454.02.000S Lift Motor Complete 1 Service Exchange

22

Lift Motor Module (A352-1A-00)

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

Parts List

Hydraulic System


- 5454.02.004 Field Coil Kit 1 BM5-3005S


1 - 55294.01.001 Drive Endhead 1 H95-003A2 - 55294.04.002 Bearing 1 BR-1073 - 55294.04.003 Drive End Bearing Circlip 1 H-0144 - 55294.04.004 Fan 1 A90-109C5 - 55309.02.001 Armature & Fan Assembly 1 BM5-31466 - 55309.02.002 Field Coil Kit 1 BM5-3005AS7 - 55309.02.003 Brush 4 A97-10128 - 5454.04.000 Brush Spring 4 B89-0169 - 55309.02.004 Brush Plate Assembly 1 A88-1064

10 - 55294.04.007 Brush Lead Assembly Kit 1 L93-2035AS11 - 55294.04.008 Bearing 1 BR-20512 - 55294.04.009 Washer - Wavy 1 H-01613 - 55309.02.005 Commutator Endhead 1 G97-102A14 - 55309.02.006 Headband Assembly 1 HB-106115 - 55309.02.000 Steer Motor Complete 115b - 55309.02.000S Steer Motor Complete 1 Service Exchange

Hydraulic System


Steer Motor Module (A353-1A-01)

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

Parts List

Flexi G4

24

Hydraulic System

Spool Valve Assembly (A353-2A)

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


1 4977.08.000 Spool Valve 12 41317 Spool Valve Mounting Bracket 13 7620.02.000 Handbrake Assembly 14 4970.03.000 Flow Regulator 25 4667.01.000 Hold Valve 1 48V6 5277.01.000 Spool Valve Micro Switch 1

55219.02.000 155219.03.000 1

8 7668.01.000 Handbrake Cable 19 41348.08 Lever 1 1 Side-shift

10 41348.07 Lever 2 1 Tilt11 41348.06 Lever 3 1 Lift12 7638.07.000 Lever Knobs 1 Side-shift13 7638.06.000 Lever Knobs 1 Tilt14 7638.05.000 Lever Knobs 1 Lift15 41391-00 Retaining Strap 116 41393 Bolt - Hex Head 1 Handbrake17 6121.10.035 Screw - Cap Head 1 M10 x 35 (cut down)18 6221.10.020 Screw - Cap Head 1 M10 x 2019 4813.01.000 Connector 2 1/4" - 3/8" BSP M/M20 6601.01.000 Screw - Cap Head 4 M4 x 25 Taptite21 4437.01.000 Blanking Plug 1 1/2" BSP22 4520.01.000 O-ring 4 1/2" Dowty23 4441.02.000 Coupler M0601021 4 1/2" - 1/2" BSP M/M24 - Spacer 225 (3729.82) Rubber Hose 126 (3729.87) Rubber Hose 127 (3729.86) Rubber Hose 128 (3729.84) Rubber Hose 129 (3729.83) Rubber Hose 130 (3729.34) Rubber Hose 1 S/S Restrictor - Mast31 (3729.12) Rubber Hose 1 S/S Spool - Mast32 (3729.85) Rubber Hose 133 (3729.6) Rubber Hose 1

34 (3729.61) Rubber Hose 135 6221.08.055 Screw - Cap Head 3 M8 x 5536 6120.08.000 Washer - Spring 3 M837 6111.06.040 Screw - Cap Head 2 M6 x 4038 - Solenoid 139 - Connector 1 To Item #3440 4521.01.000 O-ring 4 1/4" BSP Dowty41 4522.01.000 O-ring 4 3/8" BSP Dowty42 - Connector 1 To Item #3343 4914.02.000 Adjustable Elbow 1 1/2" BSP44 - Spacer 145 - Washer - Flat 1 Dowty46 6110.10.000 Washer - Flat 2 M1047 6120.10.000 Washer - Spring 2 M1048 6111.10.030 Bolt - Hex Head 2 M10 x 3049 6120.03.000 Washer - Spring 2 M350 4977.08.001 Spool Valve Lever Housing 3

Flexi G4

Hydraulic System

Spool Valve Assembly (A353-2A)

Parts List

7 Limit Switch XCM-A1022

26

Hydraulic System

Steering Column Module (A353-3A)

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


00 - Steering Assembly 1 Contains Items; 6 - 1001 - Steering Cover & Dash 1 Contains Items; 18, 36, 51, 58-61 & 63-651 - - - -2 - - - -3 - - - -4 - - - -5 - - - -6 - Nut 17 7647.11.000 Steering Wheel 1 ø 13"8 7646.06.000 Steering Column 19 - Steering Wheel Cover 1 As part of Item # 7

10 - Label 1 See A357-1A11 6120.10.000 Washer - Spring 10 M1012 41285.01 Steering Column Support 113 6110.12.000 Washer - Flat 1 M1214 41365.00 Hinge Screw 2 M12 x 2515 6110.12.000 Washer - Flat 2 M1216 6111.10.030 Bolt - Hex Head 2 M10 x 3017 7601.01.000 Adjustable Hand Lever 1 Locking Lever18 55481.01.003 Zapi Display Unit 1 Panel Kit19 4443.01.000 Connector 4 1/2" BSP - 3/8" BSP M/M20 4520.01.000 O-ring 4 1/2" BSP Dowty21 (3729.101) Rubber Hose 1 Orbital / Lock Valve22 (3729.100) Rubber Hose 1 Orbital / Lock Valve23 (3729.107) Rubber Hose 1 Priority Valve / Orbital24 (3729.105) Rubber Hose 1 Orbital / Tank Filter25 (3729.102) Rubber Hose 1 Lock Valve / Steer Motor26 (3729.103) Rubber Hose 1 Lock Valve / Steer Motor27 44001.09.000 Steel Orbital Valve 1 Load Sensing 100cc LT28 41242.08 Steering Column Mount 129 6111.10.025 Setscrew - Hex Head 4 M10 x 2530 4472.01.000 Connector 4 3/8" BSP - 3/8" BSP M/M31 4522.01.000 O-ring 5 3/8" BSP Dowty32 4973.01.000 Steering Lock Valve 133 6110.08.000 Washer - Flat 2 M8

34 6121.08.090 Screw - Cap Head 2 M8 x 9035 (3729.108) Rubber Hose 1 Lock Valve / Tank36 - - - -37 5400.01.000 Resistor 2 Paired with Item #5038 4521.01.000 O-ring 3 1/4" BSP Dowty39 - Steel Tube 240 5300.02.000 Horn 1 48 Volt41 - Swivel Hose Bracket Assembly 1 Mounting Bracket42 - Swivel Hose Bracket Assembly 1 Lower Swivel Bracket43 - Swivel Hose Bracket Assembly 1 Upper Swivel Bracket44 6121.10.100 Screw - Cap Head 2 M10 x 10045 6131.10.000 Nut - Nyloc 2 M1046 6131.12.000 Nut - Nyloc 1 M1247 C65983.01 Pressure Test Point 1 1/4" BSP48 4914.03.000 Adjustable Elbow 1 3/8" BSP - 3/8" BSP49 7307.01.000 Edging Strip 2 (/metre) 50 5400.01.000 Diode 1 Paired with Item #3751 55498.02.000 Hill Start Switch 152 55327.01.000 Reverse Horn 153 - Knob Steering Wheel 1 As part of Item # 754 7804.01.002 Signal Conditioning Module 155 42379.00 Rubber Clamp Pipe 156 6211.05.014 Bolt - Hex Head 2 M5 x 14 (Modify )57 7804.01.001 Steering Sensor 158 55508.06.000 Red LED Indicators 259 55508.07.000 Yellow LED Indicators 260 42315.00 Dashboard Fascia 161 41338.05 Steering Cowl 1 Zapi MIDI only62 41378.01 Cowl Reinforcement 1 Part of Item #6163 6121.08.035 Screw - Cap Head 4 M8 x 3564 7598.04.000 Handle 265 - Plug 4 As part of item #6466 6111.10.040 Bolt - Hex Head 4 M10 x 40

Flexi G4

Hydraulic System


Parts List


1 55508.07.000 Yellow LED Indicator 22 55508.06.000 Red LED Indicator 23 55481.01.003 Electronic Display 14 6121.08.035 Screw - Cap Head 4 M8 x 355 7598.04.000 Handle 26 55498.02.000 Hill Start Switch 17 42026 Sticker - Hill Start 18 41338.05 Steering Cowl 19 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

Flexi G4

A354

Brake System

A354-1A - Pedal Plate Module …………………………….…………. p30A354-2A - Rear Wheel Assembly ……………………………………. p31A354-3A - Brake Backplate Assembly ………………………………. p32


1 41297.04 Pedal Mounting Plate 12 55481.01.001 Accelerator Pedal Unit 1 Part of Traction Panel Kit3 - Accelerator Rubber 14 41296.03 Brake Pedal 15 55215.07.000 Brake Pedal Rubber 16 41291.01 Brake Push Rod 17 7197.04.000 Brake Master Cylinder 18 CA829802 Micro Switch 1 Traction Cut-out9 7081.01.000 Expansion Spring 1

10 41297.1 Cable Guard 111 7625.01.000 Bush - Glacier 212 6121.06.020 Screw - Cap Head 2 M6 x 2013 6121.08.025 Screw - Cap Head 2 M8 x 2514 6221.08.035 Screw - Cap Head 1 M8 x 3515 6110.08.000 Washer - Flat 3 M816 6131.08.000 Nut - Nyloc 4 M817 6111.10.020 Screw - Setscrew 2 M10 x 2018 6120.10.000 Washer - Spring 2 M1019 6221.12.030 Screw - Cap Head 1 M12 x 3020 6211.12.090 Bolt - Hex Head 1 M12 x 9021 6111.12.000 Nut - Plain 1 M1222 6131.12.000 Nut - Nyloc 1 M1223 6114.02.000 Nut - Plain 1 5/16" UNF

30

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 A354-3A00 7738.10.000 Brake Back Plate Assembly 1 Righthand; See A354-3A01 - Hub Rear Assembly 11 7738.08.000 Brake Cable 22 7738.08.002 Clip 23 6566.06.000 Grease Nipple - Angled 2 M6 45°4 6171.14.040 Bolt - Durlock 12 M14 x 405 4998.01.000 O-ring 2 ø75 x ø105 x 13mm6 7624.01.000 Taper Roller Bearing 2 320137 41278.00 Rear Hub 2 6"8 7624.02.000 Taper Roller Bearing 2 32010 50 x 80 x 209 4998.06.000 Nut - Lock 2 M45 x 1-5mm

10 4998.07.000 Washer - Lock 2 MB9 45mm11 41293.00 Grease Cover 212 6120.06.000 Washer - Spring 12 M613 6121.06.012 Screw - Button Head 12 M6 x 12

14 6131.06.012Screw - Countersunk Socket Head

6 M6 x 12

15 7635.09.000 Tyre - Rear 2 Plain Rubber 18" x 6"

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 - Brake Backplate R/H 11 - Brake Backplate L/H 12 7738.12.000 Adjuster 2 Manual3 7738.07.001 Cylinder - Wheel 24 - Common Shoe * 25 7738.07.005 Tension Spring 46 7738.07.006 Tension Spring 27 7738.07.007 Spring 48 - Lefthand Shoe * 18 - Righthand Shoe * 19 7738.07.010 Bracket Spring 4

10 - Fixed Slice 411 6111.06.016 Bolt - Hex Head 4 M6 x 1612 6120.06.000 Washer - Spring 4 M613 7738.07.008 Bleed Nipple 214 6111.12.025 Setscrew - Hex Head 2 M12 x 2515 7738.07.012 Nordlock Washer 2 M12

* - 7738.07.009 Brake Shoe Kit 1 Includes:2 x No-4 - Common Shoe1 x No-8 - Left Hand Shoe1 x No-8 - Right Hand Shoe

32

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

Parts List

Brake System

Flexi G4

A355

Control System

A355-1B - Electrical Module - Zapi Traction ..…………………………. p34 A355-1B-00 - Solenoid Switches ……………………….……... p37 A355-1B-01 - Reverse Alarm Kit ............................................ p38 A355-1B-02 - Cold Store Additions (Electrical) ...................... p39 A355-1B-02b - Cold Store Additions (Solenoid SW80A 24V). p39A355-2A - Wiring Looms …………………………………………………. p40

Control System

34

Control System

Electrical Module - Zapi Traction (A355-1B)

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

Control System

Flexi G4


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

Control System


00 - Zapi Controller Assembly 11 41283.03 Backplate 12 6211.06.030 Bolt - Hex Head 6 M6 x 303 6120.06.000 Washer - Spring 10 M64 6110.06.000 Washer - Flat 10 M65 55522.02.002 Traction Controller 1 AC3 Truck Serial No Required6 55327.01.000 Audiable Alarm 1 Reverse Horn7 6211.06.016 Bolt - Hex Head 10 M6 x 168 - Contactor Mounting Bracket 19 6211.05.012 Bolt - Hex Head 2 M5 x 12

10 C5188.04 Terminal Block 111 6210.04.016 Screw - Button Head 2 M4 x 1612 55522.02.005 Negative Terminal Post 113 6210.04.020 Screw - Button Head 2 M4 x 2014 6120.04.000 Washer - Spring 2 M415 6110.04.000 Washer - Flat 2 M416 55370.10.000 Relay Holder Blue 217 6211.03.030 Bolt - Hex Head 4 M3 x 3018 6111.03.000 Nut 4 M319 5849.02.000 11-pin Relay 2 48V20 55370.09.000 Timer Relay 221 - Fuse Holder 322 6210.04.006 Screw - Button Head 5 M4 x 623 55097.04.000 Fuse 1 5A24 55201.01.000 Fuse 2 10A25 - Fuse Holder Mounting Bracket 126 - Washer - Flat 227 55490.02.000 K4 Contactor 1 SW200-421 48V28 55490.06.000 K6 Contactor 1 SW200-261 48V29 - Contactor Mounting Bracket 130 6210.05.008 Screw - Button Head 4 M5 x 831 55427.03.000 Load Resistor 1 120Ω 50W32 55444.07.000 Fuse Holder 333 - Fuse Mounting Plate 134 55096.01.000 Fuse 2 400A35 5367.01.000 Fuse 1 100A36 55490.01.000 K5 Contactor 1 SW80B-10 48V37 - Cable Line 1 1 K4 to Fuse38 - Cable Line 2 1 K6 to Fuse39 - Cable Line 3 1 K5 to Fuse40 - Cable Line 4 1 Fuse to Traction Contactor41 - Cable Line 5 1 Traction Contactor to Negative Post42 55450.01.000 Temperature Switch 143 6211.03.010 Bolt - Hex Head 4 M3 x 1044 - K5 Label 145 - K4 Label 146 - K6 Label 147 - K9 Label 148 - K10 Label 149 6120.08.000 Washer - Spring 5 M850 6111.08.000 Nut 3 M851 6110.08.000 Washer - Flat 11 M852 6110.08.000 Washer - Flat 5 M853 6210.10.030 Bolt - Hex Head 1 M10 x 3054 6111.10.000 Nut 3 M1055 42090.01 Cable Line 6 156 6210.04.012 Screw - Button Head 2 M4 x 1257a - 48V Pin 1

55385.12.000 Battery Plug Female 1 Female Plug / Male Pins57b - 55385.13.000 Battery Plug Male 1 Male Plug / Female Pins

55385.14.000 Battery Plug Handle 1

36


Parts List

Control System

Solenoid Switches (A355-1B-00)


K4 Contactor - SW200-421 - Bypass / Hydraulic Lift Contact1 55490.02.000 K4 Complete 1 Includes Items 2 - 122 - Top Cover 13 - Fixing Screws 24 - Contact Fixtures 2 See Item #125 - Return Spring 1 See Item #126 - Fixed Contact 2 See Item #127 - Moving Contact 1 See Item #128 - Top Cover Base 19 - Plunger 1 See Item #12

10 - Coil & Magnet 111 - End Cap 112 55490.02.100 Contact Tip Kit 1 Includes; 4, 5, 6, 7, 9

K5 Contactor - SW80B-10 - Steer Contact13 55490.01.000 K5 Complete 1 Includes Items 14 - 2114 - Top Cover 115 - Fixing Screws 216 - Contact Fixtures 217 - Return Spring 1 See Item #2118 - Fixed Contact 2 See Item #2119 - Moving Contact 1 See Item #2120 - Coil & Magnet 1 See Item #2121 55490.01.100 Contact Tip Kit 1 Includes; 17, 18, 19, 20

K6 Contactor - SW200-261 - Steer ContactAs K4, except:1 55490.06.000 K6 Complete 1

12 55490.06.100 Contact Tip Kit 1

Flexi G4


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

Control System

Parts List

Reverse Alarm Kit (A355-1B-01)


1 - 55327.01.000 Audible Alarm 12 - - Cables 23 - 6607.01.000 Screw - Taptite 2 M4 x 6 Taptite4 - 6621.01.000 Washer - Flat 25 - 6111.03.000 Nut - Plain 4 M3

38


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

Parts List

Control System

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


1 - 55197.06.000 Fuse Terminal 12 - 55201.01.000 Fuse 10A 13 - 55415.01.000 Resistor 33Ω 100W 34 - 55209.01.000 Resistor 100Ω 50W 25 - 55427.09.000 Resistor 150Ω 25W 36 - 55468.02.000 Thermostat 1 RS159-20997 - 5940.01.000 SW80 24V Solenoid Switch 1 24V8 - 55115.01.000 Suppressor 1

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


00 - 5940.01.000 SW80 Complete 0 24V1 - - Top Cover 12 - - Fixing Screws 23 - - Contact Fixtures 2 See Item #94 - - Return Spring 1 See Item #95 - - Fixed Contact 2 See Item #96 - - Moving Contact 1 See Item #97 - - Coil & Magnet 18 - 5618.01.000 Auxiliary Terminal Block 1 See Item #99 - 55490.01.100 Contact Tip Kit 1 Includes; 3, 4, 5, 6, 8

Flexi G4


Parts List

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

Parts List

Control System

40

Wiring Looms (A355-2A)

fig. A355-2A: Truck Wiring Looms

Control System


1 - 42035.00 Main Wire Loom - Truck 12 - 41883.01 Wire Loom 1 Short H / B Switch Loom3 - 41883.02 Wire Loom 1 Short Spool M / Switch Loom4 - 41323.03 Wire Loom 1 To Lift / Tilt and Steer Motors5 - 42035.31 Wire Loom 1 Hillstart Push Button6 - 42082.00 Wire Loom - Panel 0 Included on Panel (not shown)7 - 41323.05 Heavy Cable No2 1 Line Contactor - Fuse8 - 41323.06 Heavy Cable No20 1 Steer & Lift / Tilt Motor Link9 - 41323.07 Heavy Cable No20 1 Steer Motor - Main

10 - 41323.08 Heavy Cable P2 1 Lift / Tilt Motor - K411 - 41323.09 Heavy Cable P4 1 Steer Motor - K512 - 42342.15 Traction Motor Cable 113 - 42342.16 Traction Motor Cable 114 - 42342.17 Traction Motor Cable 115 - - - - -16 - - - - -17 - 41883.17 Wire Loom (Keycode Switch) 1 To Keyswitch & Horn18 - 41323.18 Optional Wire Loom 1 Keycode System19 - 41323.20 Wire Loom 2 Fan Lead20 - 41323.21 Wire Loom 1 Horn Push Button21 - 41323.22 Wire Loom 1 Horn22 - 41323.23 Wire Loom 1 Reverse Alarm23 - 55523.01.006 Sensor Cable 1 To Encoder & Temperature Sensor24 - 41883.25 Wire Loom 1 Fwd / Rev Lever25 - 41323.26 Wire Loom 1 Battery Cable - Panel / Male26 - 41323.27 Wire Loom 1 Battery Cable - F / F

Flexi G4

Wiring Looms (A355-2A)

Parts List

42

Flexi G4

A356

Mast System

A356-1A - Mast Support Assembly ………......…………………................. p44A356-2A - Mast Assembly ………………………………………................... p46A356-3A - Mast Fitting ……………………………………………................. p47 A356-3A-01 - Fixed Stage Assembly ........................................... p48 A356-3A-02 - Second Stage Assembly ....................................... p50 A356-3A-03 - Third Stage Assembly ........................................... p52A356-4A - Narrow Aisle Fork Carriage Assembly ………………................ p54 A356-4A-00 - Alternate Fork Carriage Assembly ......................... p55A356-5A - Narrow Aisle Hydraulic Components Fixed Stage …................ p56A356-6A - Narrow Aisle Hydraulic Components Third Stage .................... p59

Mast System

Mast Support Assembly (A356-1A)

44

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

Mast System

Mast Support Assembly (A356-1A)


1 41249.05 Mast Support Fabrication 12 41424.01 Slewing Ring 13 6711.12.075 Set Pin - Hex Head 47 M12 x 75 Grade 10-94 - Mast Support Clamp 2 Right, part of item #15 6221.20.090 Screw - Cap Head 4 M20 x 906 6120.20.000 Washer - Spring 4 M207 6566.04.000 Grease Nipple 2 M108 7626.01.000 Bush - Glacier 2 Mast9 41343.01 Mast Retaining Washer 2

10 6120.10.000 Washer - Spring 2 M1011 6121.10.030 Screw - Cap Head 2 M10 x 3012 6612.01.000 Screw - Button Head 4 M6 x 2013 7629.03.000 Rubber Buffer 214 6588.01.000 Circlip 115 6591.01.000 Spring Clip 416 6110.24.000 Washer - Flat 4 M2417 44030.xx.000 Cylinder - Tilt 218 3526.03 Tilt Cylinder Mounting Shaft 419 4415.01.000 Connector 4 1/4" BSP - 1/4" BSP M/M20 - Spindle 121 4521.01.000 O-ring 8 1/4" BSP Dowty22 6211.14.065 Bolt - Hex Head 2 M14 x 6523 6111.14.000 Nut 2 M1424 7627.01.000 Thrust Washer 2 Glacier25 - Connector 90 2 1/4" BSP - 1/4" BSP Elbow26 4415.01.000 Connector 2 1/4" BSP - 1/4" BSP M/M27 4439.01.000 Blanking Plug 2 1/4" BSP28 41249.24 Bearing Seat 1 Part of item #129 41249.21 Articulation Shaft 130 6120.16.000 Washer - Spring 4 M1631 6210.16.055 Screw - Button Head 4 M16 x 5532 - Mast Support Clamp 1 Left, part of item #133 6566.10.000 Grease Nipple 5 M1034 6211.05.014 Bolt - Hex Head 2 M5 x 1435 - Rubber Clamp Pipe 136 - Hose Fixed Seat 1

Flexi G4

Parts List

Mast System

Mast Assembly (A356-2A)


30772A 3912mm30773A 4521mm31190 4800mm

30774A 4928mm3157D 5550mm30770A 6600mm30771A 7410mm30158 8400mm

30778A 3912mm30779A 4521mm31191 4800mm

30780A 4928mm30173 5550mm30776 6600mm30777 7410mm30159 8400mm

30184A 3912mm30785A 4521mm31192 4800mm

30786A 4928mm30185 5550mm30782 6600mm30783 7410mm30160 8400mm

46

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

-Mast Sub-Assembly Second Stage(Middle)

1

12

Mast Sub-Assembly Third Stage(Inner)

1

Parts List

Mast System

Mast Fitting (A356-3A)

1 -Mast Sub-Assembly Fixed Stage(Outer)

3 -


B350615 3912mmB350618 4050mmB350607 4200mmB350616 4521mmB351030 4620mmB350608 4800mmB350617 4928mmB351025 5010mmB351391 5220mmB351031 5400mmB350606 5550mmB350622 6000mmB351026 6210mmB350609 6600mmB351027 7020mmB351028 7200mmB350610 7410mmB350611 7620mmB351029 8010mmB350620 8204mmB350612 8220mmB350613 8400mmB350614 8610mmB351032 8820mmB350621 9000mm

Flexi G4

Fixed Stage Assembly (A356-3A-01)

1-

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

Parts List

00 Full Mast Assembly

Mast System


Ref UK Pt.No Description Qty Notes

1 - Washer - Flat n M10 2t2 7629.04.000 Rubber Buffer 2 03 6110.10.000 Washer - Flat 2 M104 6121.10.040 Screw - Cap Head 2 M10 x 40 5 6131.10.000 Nut - Nyloc 4 M10

48

Fixed Stage Assembly (A356-3A-01)

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

Parts List

Mast System



6 41410.00 Cylinder Clamp 2 07 6121.10.045 Screw - Cap Head 4 0

4200mm5010mm5550mm6000mm6600mm7020mm7620mm8010mm8610mm9000mm

9 6353.01.000 Split Pin 4 010 7694.03.000 Chain Anchor Pin 2 8234-0911 7694.02.000 Chain Anchor Bolt 2 BL0534 MB112 6111.16.000 Nut - Plain 2 M1613 6131.16.000 Nut - Nyloc 2 M1614 40558.06 Limit Switch Bracket 1 0

55219.02.000 Limit Switch 1 055219.03.000 0.00 1 0

16 6121.04.016 Screw - Cap Head 2 M4 x 1617 6120.06.000 Washer - Spring 2 M618 6610.01.000 Screw - Button Head 4 M6 x 1019 41451.11 Bulkhead Bracket 1 020 6120.06.000 Washer - Spring 2 M6


22 6566.06.000 Grease Nipple - Angled 2 M6 45°23 4143.00 Manifold 1 024 6120.08.000 Washer - Spring 2 M825 6121.08.020 Screw - Cap Head 2 M8 x 20

6596.01.000 Shim Standard 40 ID x 0-56596.03.000 0.00 Heavy Duty7671.01.000 Roller Assembly Standard7773.01.000 0.00 Heavy Duty

28 6161.10.010 Grubscrew 2 M10 x 10 29 - - - -30 41396.xx Fixed Stage Mast Fabrication 1 Mast Ref number Required

4200 045010 085550 016000 136600 167020 187620 218010 238610 269000 28

Flexi G4

41404.xx

2

Parts List (cont-)

2

26

41410

21

For UK Masts replace .XX

n

Leaf Chain

- To Third Stage Mast, Lower

15

8

Mast System


Cylinder - Main Lift(Fixed Stage)

27

LIFT HEIGHT .XX

4

Second Stage Assembly (A356-3A-02)

50

Second Stage Assembly (A356-3A-02)

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

Mast System


Parts List


6596.01.000 Standard 40 ID x 0-56596.03.000 Heavy Duty7671.01.000 Standard7773.01.000 Heavy Duty

3 40558.03 Reaction Block 1 -4 6131.06.025 Setscrew - Countersunk 2 M6 x 255 6150.30.000 Washer - Flat 2 M30 Light6 40149 Hose Pulley 2 -7 40206 Bearing Spacer 3 -8 40148.01 Chain Pulley 2 -9 7672.01.000 Pulley Bearing 2 6306-2RS

10 6428.01.000 Circlip 2 72mm Internal11 3169.35.000 Spacer 1 -12 41408.01 Hose Pulley 1 -13 6150.30.000 Washer - Flat 1 M30 Light14 41409 Pulley Shaft 1 2 30 OD x 112 BSP15 6120.08.000 Washer - Spring 2 M816 6111.08.016 Setscrew 2 M8 x 1617 0 Second Stage Mast Fabrication 1 Mast Ref number required

Flexi G4

Third Stage Assembly (A356-3A-03)

4

Parts List

1

2


Roller Assembly

n

Mast System

Shim


1 - Washer - Flat n M10 2t2 7629.04.000 Rubber Buffer 2 03 6110.10.000 Washer - Flat 2 M104 6121.10.035 Screw - Cap Head 2 M10 x 35 5 6111.10.016 Screw - Cap Head 2 M10 x 166 6120.10.000 Washer - Spring 2 M107 41409.01 Pulley Shaft 2 2 0

52

Third Stage Assembly (A356-3A-03)

Parts List (cont-)

Parts List

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


Mast System



9 6353.01.000 Split Pin 8 -10 7694.03.000 Chain Anchor Pin 4 8234-0911 7694.02.000 Chain Anchor Bolt 4 BL0534 MB112 6111.16.000 Nut - Plain 4 M1613 6131.16.000 Nut - Nyloc 4 M1614 6150.30.000 Washer - Flat 2 M30 Light15 41407 Chain Pulley 2 -16 7672.01.000 Pulley Bearing 2 6306-2RS17 6428.01.000 Circlip 2 72mm Internal18 40206.02 Bearing Spacer 2 -19 41408 Hose Pulley 2 -20 6120.08.000 Washer - Spring 2 M821 6111.08.016 Setscrew 2 M8 x 16


23 6161.08.010 Grubscrew 2 M8 x 1024 41406 Pulley Yoke 2 -25 6161.08.020 Grubscrew 4 M8 x 20

6596.01.000 n Standard 40 ID x 0-56596.03.000 0 Heavy Duty7671.01.000 4 Standard7773.01.000 0 Heavy Duty

28 41410.01 Cylinder Clamp 2 29 6131.08.000 Nut - Nyloc 4 M830 6150.30.000 Washer - Flat 4 M30 Light31 0 Third Stage Mast Fabrication 1 Mast Ref number required

Flexi G4

27

Shim

22Cylinder - Free Lift(Third Stage)

2

26

Mast System

Narrow Aisle Fork Carriage Assembly (A356-4A)

Roller Assembly

287694.01.000

(length as required)Leaf Chain

Parts List (cont-)

41405.xx


1 41411.xx Side-Shift 1 Bolzoni 860mm7671.01.000 Roller Assembly 4 Standard7773.01.000 0.00 0 Heavy Duty

3 7694.02.000 Chain Anchor Bolt 2 BL 0534 MB14 7694.03.000 Chain Anchor Pin 2 8234-095 6111.16.000 Nut - Plain 2 M166 6131.16.000 Nut - Nyloc 2 M167 6353.01.000 Split Pin 2 -

6596.01.000 Shim n Standard 40 ID x 0-56596.03.000 0.00 0 Heavy Duty

9 41936.03 Fork 2 1150 mm10 6566.06.000 Grease Nipple 4 M611 6121.16.025 Screw - Cap Head 1 M16 x 2512 6120.16.000 Washer - Spring 1 M1613 6121.08.012 Screw - Cap Head 1 M8 x 1214 6120.08.000 Washer - Spring 1 M815 4997.21.005 Upper Wear Pad - Right 1 -16 4997.21.004 Upper Wear Pad - Left 1 -17 4997.21.002 Lower Wear Pad - Right 1 -18 4997.21.003 Lower Wear Pad - Left 1 -19 4997.21.001 Cylinder - Side-shift 1 -

54

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

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

Parts List

2

8

Narrow Aisle Fork Carriage Assembly (A356-4A)

Mast System


1 - Mast Carriage Assembly 1 Kaup Standard Mast2 - Fork Carriage 1 Kaup Heavy Duty3 4997.44.023 Bush - Glacier 2 -4 4997.44.025 Groove Ring 2 -5 4997.44.022 Washer 2 -6 4997.44.024 Stripper 2 -7 4997.44.004 Piston Rod 2 -8 4997.79.001 Holder 2 -9 6121.12.060 Screw 2 M16 x 6010 4997.44.019 Guide Roller 2 011 4997.44.035 Nut 4 M3012 4997.44.033 Grease Nipple 2 M813 4997.44.005 Sliding Piece 13 or 13a13a 4997.44.06 0.00 014 4997.44.032 Grease Nipple 2 M815 6121.12.030 Stop Bolt 2 -16 6120.16.000 Washer - Spring 1 M1617 6121.16.025 Screw - Cap Head 1 M16 x 2518 41936.03 Fork 2 1150 mm

7671.01.000 Roller Assembly Standard7773.01.000 0.00 Heavy Duty

20 - Chain Anchor Assembly 2 -

Flexi G4

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

4

4

19

Mast System

Parts List

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


4200mm4620mm4800mm5010mm5400mm5550mm6000mm6210mm6600mm7020mm7200mm7410mm7620mm8010mm8220mm8400mm8610mm8820mm9000mm

56


Free Lift Feed Pipe

Mast System

Parts List (cont-)

See Note A(page 58)

1

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

Parts List

1

Important:- All masts are stamped either UK or TW, please state when ordering parts.


4200mm4620mm4800mm5010mm5400mm5550mm6000mm6210mm6600mm7020mm7200mm7410mm7620mm8010mm8220mm8400mm8610mm8820mm9000mm4200mm4620mm4800mm5010mm5400mm5550mm6000mm6210mm6600mm7020mm7200mm7410mm7620mm8010mm8220mm8400mm8610mm8820mm9000mm4200mm4620mm4800mm5010mm5400mm5550mm6000mm6210mm6600mm7020mm7200mm7410mm7620mm8010mm8220mm8400mm8610mm8820mm9000mm

Flexi G4

41442.xx

41441.xx

3 Main Lift Feed Pipe

2 Main Lift Feed Pipe 1

Parts List (cont-)

1

Mast System

1

4See Note B(page 58)

Side-Shift Feed Pipe



4200mm4620mm4800mm5010mm5400mm5550mm6000mm6210mm6600mm7020mm7200mm7410mm7620mm8010mm8220mm8400mm8610mm8820mm9000mm

6 Manifold 1 Also see A356-3 Item #237 4971.05.000 Safety Valve 1 0.008 - Blanking Plug 1 0.009 4627.04.000 Pipe Clamp 3 8mm Twin

10 44057.12.000 Connector - Male 2 1/2" BSP - 15mm11 44057.13.000 Bulkhead Coupling 1 15mm12 44057.14.000 Connector - Male 4 3/8" BSP - 10mm13 44057.15.000 Connector 2 8mm

5500mm6600mm7620mm8610mm5500mm Also see6600mm A356-67620mm Item #48610mm

16 41451.11 Bulkhead Bracket 1 0.0017 4627.05.000 Pipe Clamp 4 15mm Single18 6111.08.020 Setscrew 2 M8 x 2019 6610.01.000 Screw - Button Head 3 M5 x 1220 6111.06.016 Bolt - Hex Head 2 M6 x 1621 6120.08.000 Washer - Spring 2 M822 4245.03.000 Rupture Valve - Set to 1-2mm 2 3/8" Part of Free Lift Cylinder23 6120.06.000 Washer - Spring 2 M624 - Spring 1 0.0025 - O-ring 1 0.0026 - Circlip 1 0.0027 41437.00 Manifold 1 Also see A356-3 Item #2328 - Connector 1 0.0029 - - - -30 - - - -31 - Plug 1 0.0032 - Ring 1 0.00

33 - 44095.01.000Coned-stud Adapter

(Not Shown)1 Required to connect a mast stamped

with TW to an NA truck chassis ONLY.

41522.xx Free Lift Feed Pipe 144063.04.000 Walform Seal (15mm) 244057.16.000 Straight Coupling (15mm) 1

41484.xx Free Lift Feed Pipe 141523.xx Sideshift Feed Pipe 1

44063.01.000 Walform Seal (8mm) 244057.18.000 Straight Coupling (8mm) 1

41485.xx Sideshift Feed Pipe 141524.xx Sideshift Feed Pipe 1

44063.01.000 Walform Seal (8mm) 244057.18.000 Straight Coupling (8mm) 1

41486.xx Sideshift Feed Pipe 1

58

C See Item #5All four items required as NA equivelant

to TW item #5

B See Item #4All four items required as NA equivelant

to TW item #4

5See Note C

(below)Side-Shift Feed Pipe

See Item #1All four items required as NA equivelant

to TW item #1

1

41452.xx

Mast System

15 41453.xxSide-Shift Rubber Hose Assembly

2

14Free Lift Rubber Hose Assembly

1

A

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

Flexi G4

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

Parts List

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

Mast System


5500mm6600mm7620mm8610mm5500mm6600mm7620mm8610mm5500mm6600mm7620mm8610mm5500mm Also See6600mm A356-57610mm Item #158610mm

5 C Bulkhead Coupling 3 8mm6 - Nut - Lock 4 0.00

5500mm6600mm7620mm8610mm

8 - Feed Pipe 1 0.009 - Rubber Hose 1 0.00

10 - Rubber Hose 1 0.0011 44057.13.000 Bulkhead Coupling 2 15mm12 - Connector - Elbow 3 To A356-3-03 #2213 - Rubber Hose 2 0.0014 - Connector - T 1 To A353-1A #19 & A356-3-03 #2215 - Pipe 1 8mm diameter16 - Connector - Elbow 3 0.0017 - Pipe Clamp 2 0.0018 - Nut 1 0.0019 4521.01.000 O-ring 2 1/4" BSP Dowty20 4976.01.000 Nylon Pipe 1 8mm diameter (/metre)21 - - - -22 6211.08.016 Bolt - Hex Head 2 M8 x 1623 6120.08.000 Washer - Spring 2 M8

60

1 Side-shift Feed Pipe 141487.xx

3 Side-Shift Hose - Secondary 2

2 Side-shift Feed Pipe 141488.xx

41454.xx

7 Rubber Hose 1

4 Side-Shift Hose - Primary 241453.xx

41452.xx

Flexi G4

A357

Accessory System

A357-1A - Labels ..……………………………….………………………… p62A357-2A - Seal Kit …………………………….…………………………… p64A357-3A - Cold Store Additions (Mechanical) ..…………………………. p64

Accessory System

Labels (A357-1A)

62

fig. A357-1A-1: Labels

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

Accessory System

Labels (A357-1A)

Parts List


1 Capacity Plate 40222-36 1 Printed by Design dept- - - - -2 Warning Label 40084-69 1 General Operation3 Warning Label 40084-00 2 Hand Crush - Side Force4 Warning Label 40084-01 2 Foot Crush - Side Force5 Warning Label 40084-70 1 Tip Over6 Warning Label 40084-04 2 Overheads Loads7 Warning Label 41344-?? 1 Seat Lift8 Warning Label 41431-?? 1 Battery Retainers- - - - -9 Instruction Label 40084-12 1 Lifting Points

10 Instruction Label 40113-03 1 Pedal Functions11 Instruction Label 40129-00 1 Transmission Oil Fill Point12 Instruction Label 40129-01 1 Hydraulic Oil Fill Point13 Instruction Label 40155-03 1 Battery Charge Label14 Instruction Label 7207.01.00 4 Lifting Points15 Instruction Label 41579-00 1 Horn Symbol16 Instruction Label 41930-00 1 Light Symbol17 Instruction Label 42026-00 1 Hillstart Symbol- - - - -

18 Decal - Flexi Logo 7618.09.000 1 Set w/out flashes- - - - -

19 Instruction Label 40084-71 1 Battery Charge Label

Flexi G4

Accessory System

Seal Kit (A357-2A)

Parts List


41404.200 GKN41404.300 Tail Lift41404.400 Rangers41405.200 GKN41405.300 Tail Lift41405.400 Rangers

44030.14.001 TW44030.04.002 NA4997.21.006 Standard4997.21.010 Cold Store

5 - 4997.44.017 Seal Kit - Sideshift Cylinder(for A 2 Seal Kit A

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


1 - 3735-03 Axel Pivot Shaft 12 - 3526-05 Tilt Cylinder Mounting Shaft 43 - - Cold Store Grease a/r Shell Alvania RA4 - - Transmission Oil 0.8 Litre, Aral Degol PAS1505 - - Hydraulic Oil 50 Litres, Mobil Aero HFACastrol Hyspin AWH-1-56 - 55413.03.000 Low Temperature 4 Core 6m Igus CF9.10.047 - 41715.01 Traction Motor Brush Cover 18 - 41715.02 Traction Motor Brush Cover 19 - 0.00 Air Sentry 1 MP Filtri No. D-101

10 - 0.00 Air Sentry Adaptors 2 MP Filtri No. A-10311 - TB194 Technical Bulletin ref

64

1 B350738 Seal Kit - Main Lift Cylinder 2

2 B350739 Seal Kit - Free Lift Cylinder 2

3 B350740 Seal Kit - Tilt Cylinder 2

4 B350802 Seal Kit - Sideshift Cylinder 1

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

Parts List

A358-1A - By Part Name .…………………………………………................ iA358-2A - By Part Reference Number - NA .……………………............. xiiiA358-3A - By Part Reference Number - TW ..………………..……........ xxiii

A358

Index

ssue E

Flexi G4

1

allan

oved

allanallan

3

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5

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7

9

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11

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13

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15

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17

19

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21

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23

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25

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27

29

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33

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35

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37

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41

43

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45

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47

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49

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51

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55

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61

Flexi G4

63

65

Documents

Flexi G4 Parts Manual - Narrow Aisle Inc