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
15 M1606-M24 6120.24.000 Washer - Spring 1 M24
16 M1402-M20*140 6211.20.140 Bolt - Hex Head 4 M20 x 140
17 M1401-M20*60 6211.24.100 Bolt - Hex Head 1 M24 x 100
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
24 M1606-M8 6120.08.000 Washer - Spring 2 M8
25 M1424-M8*20 6121.08.020 Screw - Cap Head 2 M8 x 20
26 3004375 42330.00 Cable Protection plate 1
27 M1606-M10 6120.10.000 Washer - Spring 3 M10
28 M1423-M10*20 6121.10.020 Screw - Cap Head 2 M10 x 20
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
31 M1401-M10*20 6121.10.020 Screw - Cap Head 1 M10 x 20
32 M1606-M8 6120.08.000 Washer - Spring 1 M8
33 M1401-M8*20 6121.08.020 Screw - Cap Head 1 M8 x 20
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
Ref TW Pt No NA Pt.No Description Qty Notes
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
10 M0909-32013 7624.01.000 Taper Roller Bearing 6 32013
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
20 M1401-M10*30 6121.10.030 Screw - Cap Head 16 M10 x 30
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
33 M0909-32009 4978.15.004 Taper Roller Bearing 1 32009
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
54 M1605-M10 6120.10.000 Washer - Spring 39 M10
55 M1605-M8 6120.08.000 Washer - Spring 18 M8
56 0 55492.08.001 Encoder Sensor 1 Schabmuller
7
Flexi G4
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)
Ref TW Pt No NA Pt.No Description Qty Notes
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
3 M1605-M12 6120.12.000 Washer - Spring 6 M12
4 M1424-M12*40 6211.12.040 Bolt - Hex Head 8 M12 x 40
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
8 M1606-M20 6120.20.000 Washer - Spring 10 M20
9 M1401-M20*50 6121.20.050 Screw - Cap Head 2 M20 x 50
10 30372 7093.01.000 Brass Tee Piece 1
11 M1606-M6 6120.06.000 Washer - Spring 4 M6
12 M1401-M6*40 6121.06.040 Screw - Cap Head 1 M6 x 40
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
18 M1602-M8 6120.08.000 Washer - Spring 4 M8
19 M1401-M8*25 6121.08.025 Screw - Cap Head 8 M8 x 25
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
23 M1401-M4*45 6121.04.045 Screw - Cap Head 8 M4 x 45
24 30261C 41320.01 Side Ballast 1 Right Hand Side
25 M1401-M20*70 6121.20.070 Screw - Cap Head 8 M20 x 70
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
30 M1606-M10 6120.10.000 Washer - Spring 2 M10
31 - 41286 Steer Motor Mounting Plate 1
32 - 4690.01.000 Pipe Clip (not shown) 2 1/4"
11
Flexi G4
Parts List
Chassis Fitting System
Chassis Kit (A352-1A)
Ref TW Pt No NA Pt.No Description Qty Notes
1 M1401-M12*40 6121.12.040 Screw - Cap Head 8 M12 x 40
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
10 M1606-M12 6120.12.000 Washer - Spring 8 M12
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
Chassis Kit (A352-1A)
Chassis Fitting System
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
Chassis Fitting System
Chassis Kit (A352-1A)
fig. A352-1A-01: Additional Chassis Parts, exploded view
Parts List
14
Flexi G4
fig. A352-2A: Seat & Covers, Exploded View
Chassis Fitting System
Seat and Covers (A352-2A)
Ref NA Pt.No Description Qty Notes
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
31 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
Chassis Fitting System
Seat and Covers (A352-2A)
Parts List
1D180416
Ref NA Pt.No Description Qty Notes
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
Chassis Fitting System
Overhead Guard (A352-3A)
Flexi G4
Parts List
Ref TW Pt No NA Pt.No Description Qty Notes
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
Chassis Fitting System
Battery Tray Assembly (A352-4A)
fig. A352-4A: Battery Tray Assembly
Flexi G4
Ref NA Pt.No Description Qty Notes
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
Chassis Fitting System
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
Ref TW Pt No NA Pt.No Description Qty Notes
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
30 M1401-M8*35 6221.08.035 Screw - Cap Head 16 M8 x 35
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
34 M1606-M8 6120.08.000 Washer - Spring 20 M8
35 M1606-M6 6120.06.000 Washer - Spring 12 M6
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
Oil Tank Module (A353-1A)
Parts List
Flexi G4
Ref TW Pt No NA Pt.No Description Qty Notes
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
Oil Tank Module (A353-1A)
Flexi G4
Ref TW Pt No NA Pt.No Description Qty Notes
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
Oil Tank Module (A353-1A)
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
Ref NA Pt.No Description Qty Notes
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
Ref NA Pt.No Description Qty Notes
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
27 6111.10.025 Setscrew - Hex Head 4 M10 x 25
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
Steering Column Module (A353-3A)
Parts List
Ref NA Pt.No Description Qty Notes
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 Column Module (A353-3A)
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
Ref NA Pt.No Description Qty Notes
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
Ref NA Pt.No Description Qty Notes
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)
Ref NA Pt.No Description Qty Notes
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
14 6111.12.025 Setscrew - Hex Head 2 M12 x 25
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
Electrical Module - Zapi Traction (A355-1B)
fig. A355-1B-2: Electrical Module - Zapi Traction Components
Ref NA Pt.No Description Qty Notes
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
11 6210.04.016 Screw - Button Head 2 M4 x 16
12 55522.02.005 Negative Terminal Post 1
13 6210.04.020 Screw - Button Head 2 M4 x 20
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
22 6210.04.006 Screw - Button Head 5 M4 x 6
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
30 6210.05.008 Screw - Button Head 4 M5 x 8
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
38 - Cable Line 2 1 K6 to Fuse
39 - Cable Line 3 1 K5 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
56 6210.04.012 Screw - Button Head 2 M4 x 12
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
Electrical Module - Zapi Traction (A355-1B)
Parts List
Solenoid Switches (A355-1B-00)
Ref NA Pt.No Description Qty Notes
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
Electrical Module - Zapi Traction (A355-1B)
fig. A355-1B-00: Solenoid Switches K4 & K6 fig. A355-1B-00: Solenoid Switch K5
Reverse Alarm Kit (A355-1B-01)
Ref TW Pt No NA Pt.No Description Qty Notes
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
Electrical Module - Zapi Traction (A355-1B)
Cold Store Additions (Electrical) (A355-1B-02)
Ref TW Pt No NA Pt.No Description Qty Notes
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)
Ref TW Pt No NA Pt.No Description Qty Notes
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
Electrical Module - Zapi Traction (A355-1B)
Parts List
40
Flexi G4
Control System
Wiring Looms (A355-2A)
fig. A355-2A: Truck Wiring Looms
Ref TW Pt No NA Pt.No Description Qty Notes
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
13 - 42342.16 Traction Motor Cable 1
14 - 42342.17 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
Ref NA Pt.No Description Qty Notes
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
12 6612.01.000 Screw - Button Head 4 M6 x 20
13 7629.03.000 Rubber Buffer 2
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
Ref TW Pt No NA Pt.No Description Qty Notes
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
Ref TW Pt No NA Pt.No Description Qty Notes
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
Mast Fitting (A356-3A)
fig. A356-3A-01: Mast Fitting - Fixed Stage, Exploded View
Parts List
Fixed Stage Assembly (A356-3A-01)
Ref UK Pt.No Description Qty Notes
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
18 6610.01.000 Screw - Button Head 4 M6 x 10
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
Mast Fitting (A356-3A)
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
Mast Fitting (A356-3A)
fig. A356-3A-02: Mast Fitting - Second Stage, Exploded View
Second Stage Assembly (A356-3A-02)
Ref UK Pt.No Description Qty Notes
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
13 6150.30.000 Washer - Flat 1 M30 Light
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
Mast Fitting (A356-3A)
Roller Assembly
Parts List
1
Mast System
Third Stage Assembly (A356-3A-03)
Ref UK Pt.No Description Qty Notes
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
Mast Fitting (A356-3A)
fig. A356-3A-03: Mast Fitting - Third Stage, Exploded View
Third Stage Assembly (A356-3A-03)
Ref UK Pt.No Description Qty Notes
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
14 6150.30.000 Washer - Flat 2 M30 Light
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
30 6150.30.000 Washer - Flat 4 M30 Light
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
Mast Fitting (A356-3A)
27
Shim
22
Flexi G4
Ref UK Pt.No Description Qty Notes
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)
Ref UK Pt.No Description Qty Notes
1 #REF! #REF! #### #REF!
2 #REF! #REF! 1 #REF!
3 #REF! #REF! 2 #REF!
4 #REF! #REF! 2 #REF!
5 #REF! #REF! 2 #REF!
6 #REF! #REF! 2 #REF!
7 #REF! #REF! 2 #REF!
8 #REF! #REF! 2 #REF!
9 #REF! #REF! 2 #REF!
10 #REF! #REF! 2 #REF!
11 #REF! #REF! 4 #REF!
12 #REF! #REF! 2 #REF!
13 #REF! #REF! #REF!
13a #REF! #REF! #REF!
14 #REF! #REF! 2 #REF!
15 #REF! #REF! 2 #REF!
16 #REF! #REF! 1 #REF!
17 #REF! #REF! 1 #REF!
18 #REF! #REF! 2 #REF!
7671.01.000 Roller Assembly Standard
7773.01.000 0.00 Heavy Duty
20 #REF! #REF! 2 #REF!
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 UK Pt.No Description Qty Notes
#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
Ref UK Pt.No Description Qty Notes
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
Narrow Aisle Hydraulic Components - Fixed Stage (A356-5A)
0
0
Flexi G4
Ref UK Pt.No Description Qty Notes
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
19 6610.01.000 Screw - Button Head 3 M5 x 12
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
Narrow Aisle Hydraulic Components - Fixed Stage (A356-5A)
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
Ref NA Pt.No Description Qty Notes
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
10 M0501088 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
13 M0501089 Rubber Hose 2 1/4" BSP Hose
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
Ref NA Pt.No Description Qty Notes
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
Ref TW Pt No NA Pt.No Description Qty Notes
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
Ref TW Pt No NA Pt.No Description Qty Notes
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
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