FLEXI HILOAD Parts Manual - - Narrow Aisle Inc · 2019-11-20 · 7 4980.01.000 Hydraulic Steer Motor 1 Danfoss OMSW400 8 6120.12.000 Washer - Spring 8 M12 9 4975.06.000 Brass Straight

42408-00 Issue C

FLEXI HILOADParts Manual

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2A350-1A - Document Revision Details 2

346

A352 - Chassis Fitting System 9A352-1A - Chassis Kit 10

A352-1A-00 - Steering Motor Extension 12A352-1A-01 - Additional Chassis Parts 13

A532-2A - Seat and Covers 14A352-3A - Overhead Guard 16A352-4A - Battery Tray Assembly 17A352-5A - Controls Assembly 18

A353 - Hydraulic System 19A353-1A - Oil Tank Module 20

A353-1A-00 - Lift Motor Module 22A353-1A-01 - Steer Motor Module 23

A353-2A - Spool Valve Assembly 24A353-3A - Steering Column Module 26

A353-3A-00 - Steering Cover and Dash 28

A354 - Brake System 29A354-1A - Pedal Plate Module 30A354-2A - Rear Wheel Assembly 31A354-3A - Brake Backplate Assembly 32

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

A355-1B-00 - Solenoid Switches 37A355-1B-01 - Reverse Alarm Kit 38A355-1B-02 - Cold Store Additions (Electrical) 39A355-1B-02b - Cold Store Additions (Solenoid SW80A 24V) 39

A355-2A - Wiring Looms 40

A356 - Mast System 43A356-1A - Mast Support Assembly 44A356-2A - Mast Assembly 46A356-3A - Mast Fitting 47

A356-3A-01 - Fixed Stage Assembly 48A356-3A-02 - Second Stage Assembly 50A356-3A-03 - Third Stage Assembly 52

A356-4A - Narrow Aisle Fork Carriage Assembly 54A356-4A-00 - Alternative Fork Carriage Assembly 55

A356-5A - Narrow Aisle Hydraulic Components - Fixed Stage 56A356-6A - Narrow Aisle Hydraulic Components - Third Stage 59

A357 - Accessory System 61A357-1A - Labels 62A357-2A - Seal Kit 64A357-3A - Cold Store Additions (Mechanical) 64

65A358-1A - By Part Name i

xiiixxiii

A358 - Index

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

Contents

A350 - Revisions

A351 - Transmission SystemA351-1A - Front Axle AssemblyA351-2A - Axle and Transmission

Rev Date Revised By

A 21 / 05 / 2013 H ClemmetB 06 / 06 / 2013 H ClemmetC 10 / 07 / 2013 R. Bennett

2

First Issue P CaSeat Latch and Sales Values added P CaUpdate P Ca

Revisions

Document Revision Details (A350-1A)

Description Appr

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A351

TransmissionSystem

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

4Fle

Transmission System

Front Axle Assembly (A351-1A)

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

Ref NA Pt.No Description Qty

00 7661.09.000 Front Wheel Assembly 201 4978.15.000 Transmission Assembly 11 7635.14.000 Tyre - Front 22 41218.00 Hub 23 41288.03 Axle Support Fabrication 14 - Pin 15 - Washer 16 41288.04.02 Crossbeam 17 41045.08 Front Counterweight 18 7644.01.000 Bearing 29 6422.01.000 Circlip 2

10 6121.20.060 Screw - Socket Cap Head 111 - Washer 112 6211.20.070 Bolt - Hex Head 113 6120.20.000 Washer - Spring 514 6566.04.000 Grease Nipple 215 6120.24.000 Washer - Spring 116 6211.20.140 Bolt - Hex Head 417 6111.24.100 Screw - Hex Head 218 42380.00 Terminal Mounting Plate 119 55530.01.000 Terminal Block 120 6110.06.000 Washer - Flat 221 6120.06.000 Washer - Spring 222 6121.06.016 Screw - Cap Head 223 6110.08.000 Washer - Flat 224 6120.08.000 Washer - Spring 225 6121.08.020 Screw - Cap Head 226 42330.00 Cable Protection plate 127 6120.10.000 Washer - Spring 328 6121.10.020 Screw - Cap Head 229 55492-08-000 Traction Motor 1 AC Schabmueller30 - Axle Clamp 231 6121.10.020 Screw - Cap Head 132 6120.08.000 Washer - Spring 133 6121.08.020 Screw - Cap Head 134 4978.15.005 Wheel Nut 12

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Parts List

Transmission System

Front Axle Assembly (A351-1A)

6Fle

Transmission System

Axle and Transmission Assembly (A351-2A)

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

Transmission System

Ref NA Pt.No Description Qty Notes

00 4978.15.000 Transmission Assembly 1 Parts: All excluding 51

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

02 - Differential Case 1 Parts: 28, 291 300095 Front Tyre Base Axle 12 30092 Gear Casing 13 30088 + 30094 Spacer 24 M1308.10*32 Key 1 10 x 8 x 325 30091 Cover Plate 26 - Bolt 6 M8 x 207 4978.15.002 Taper Roller Bearing 3 303078 30074 Intermediate Gear 19 30073 Wheel-Helical 1

10 7624.01.000 Taper Roller Bearing 6 3201311 30093 Gear Casing 2 112 M1301.16*20 Pin 2 16 x 2013 30090 Connecting Shaft 114 M1301.16*40 Pin 4 16 x 4015 30089 Front Tyre Base Axle 116 4978.15.001 O-ring 2 TB80 x 105 x 13 (ACM)17 30085 Front Hub 218 30086 Axle Screw 1219 - O-Ring 220 6121.10.030 Screw - Cap Head 16 M10 x 3021 M1422.CBS5.8 Screw - Cap Head 6 CBS5-822 M1301.10*30 Pin 4 10 x 3023 30083 Nut - Lock 224 30084 Nut - Lock 2 025 30079 Front Axle-Long 1 026 M1401.M10*30 Bolt - Hex Head 12 027 31502017 Differential Gear 2 028 30082 Differential Case 1 M10 x P1-25 x 3029 30081 Differential Case 1 030 32502009 Washer - Flat 2 031 M1402.M8*65 Bolt - Hex Head 12 M8 x 6532 30078 Front Axle-Short 1 033 4978.15.004 Taper Roller Bearing 1 3200934 4978.15.010 Input Pinion-Helical 135 30071 Spacer 136 - - - -37 30075 Helical Gear 138 92502010 Breather 239 32502015 Differential Gear 440 32502014 Differential Washer 441 30080 Differential Spider 142 - Bolt 643 92502010 Screw Plug 1 Breather44 4978.15.018 Washer 145 - Washer 1

6111.10.030 Bolt - Hex Head 7 M10 x 306211.10.025 Bolt - Hex Head 1 M10 x 25

47 4978.12.014 O-ring 1 Output shaft seal ø42 x ø72 x 8mm48 - Bung 249 - Bolt 550 4978.15.005 Nut - Wheel 1251 55492-08-000 Traction Motor 1 AC Schabmueller52 4978.15.017 Shim 253 6110.10.000 Washer - Flat 8 M1054 6120.10.000 Washer - Spring 39 M1055 6120.08.000 Washer - Spring 18 M8

Flexi HILOAD

Parts List

46

Transmission System

Axle and Transmission Assembly (A351-2A)

8

Flexi HILOAD

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

Chassis Fitting System

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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 41265.32 Chassis Fabrication 1

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

42181.01 1 Left-hand42181.02 1 Right-hand

2 6110.12.000 Washer - Flat 4 M123 6120.12.000 Washer - Spring 6 M124 6211.12.040 Bolt - Hex Head 8 M12 x 405 41328.02 Quarter Ballast 1 Left Hand Side6 6453.01.000 Roll Pin 27 41328.01 Quarter Ballast 1 Right Hand Side8 6120.20.000 Washer - Spring 10 M209 6121.20.050 Screw - Cap Head 2 M20 x 50

10 7093.01.000 Brass Tee Piece 111 6120.06.000 Washer - Spring 4 M612 6121.06.040 Screw - Cap Head 1 M6 x 4013 6581.03.000 Brake Pipe 1 R/H Wheel to Tee14 6581.04.000 Brake Pipe 1 L/H Wheel to Tee15 6581.05.000 Brake Pipe 1 Tee to Brake Master Cylinder16 6517.02.000 Hole Insert 6 Side Ballast ø42mm17 41345.00 Battery Plug Bracket 118 6120.08.000 Washer - Spring 4 M819 6121.08.025 Screw - Cap Head 8 M8 x 2520 41320.02 Side Ballast 1 Left Hand Side21 55131.14.000 Fan 2 48 Volt22 6110.04.000 Washer - Flat 8 M423 6121.04.045 Screw - Cap Head 8 M4 x 4524 41320.01 Side Ballast 1 Right Hand Side25 6121.20.070 Screw - Cap Head 8 M20 x 7026 - Anti-Slip Plate Left 127 - Anti-Slip Plate Right 128 41318.00 Electrical Mounting Bracket 129 6111.10.030 Bolt 2 M10 x 3030 6120.10.000 Washer - Spring 2 M1031 41286.00 Steer Motor Mounting Plate 132 4690.01.000 Pipe Clip (not shown) 2 1/4"

Flexi HILOAD




Parts List

1d Lower Step Plate


1 6121.12.040 Screw - Cap Head 8 M12 x 402 6111.12.000 Nut - Plain 8 M123 41535.00 Steer Pinion Shaft 14 7735.01.000 Bearing 2 6210-2RSI ø90 x ø20 x 50mm5 41536.01 Bearing Housing 1 To suit Danfoss6 6588.01.000 Circlip 1 M507 4980.01.000 Hydraulic Steer Motor 1 Danfoss OMSW4008 6120.12.000 Washer - Spring 8 M129 4975.06.000 Brass Straight Fitting 1 1/4" BSP - 8mm T

10 4443.01.000 Connector - Male 2 1/2" - 3/8" BSP (to Steer Lock Valve)11 4520.01.000 Seal 2 1/2" BSP Dowty12 - Tee Connector 113 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

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Additional Chassis Parts (A352-1A-01)


1 41265.32 Chassis Fabrication 12 41577.00 Battery Retaining Assembly 1

2a 41577.01 Battery Tank Fixed Support 1 Part of item 22b 41577.02 Latch 1 Part of item 22c 41577.03 Pin 1 Part of item 23 6355.01.001 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 6610.01.000 Bolt - Button Head 4 M4 x 25

10 6110.04.000 Washer - Flat 4 M411 6120.04.000 Washer - Spring 5 M412 42032.02 Battery Lid Bracket 1 Right-hand13 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 M422 41896.01 Pivot Pin 1 Also sold as a set - 41896.0023 44079.01.000 Rotary Shaft 1 95 x 75 x 10 mm24 41896.02 Seal Cap 1 Also sold as a set - 41896.0025 44078.01.000 Roller bearing 1 160 x 75 x 37 mm26 41896.03 Seal Plate 1 Also sold as a set - 41896.00


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

Parts List

41302.30


Flexi HILOAD

14Fle

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


Seat and Covers (A352-2A)


0 0 0 0 01 41339.03 Battery Lid 1 02 41337.10 Front Electronics Cover 1 03 41390.00 Arm Rest Cushion 1 04 41385.00 Seat Pan 1 05 41336.04 Front Nose Cone Cover 1 06 7659.01.000 Gas Strut 1 650N7 42046.00 Seat Wire Plate 1 Protects Seat Switch Cable8 55497.01.000 Document Holder 1 09 7633.27.000 Seat 1 MSG 20 inc- Belt (PVC)

10 41321.06 Floor Plate 1 011 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 1 017 6121.10.040 Screw - Cap Head 2 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 1 021 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 1 025 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 3 031 7703.03.000 Rubber Buffer 3 032 6110.06.000 Washer - Flat 2 M633 6121.06.020 Screw - Cap Head 2 034 7633.27.005 Seat Runners 2 035 - Pipe Connector 1 036 - 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 1 039 - - - -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 1 046 - - - -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 M40 0 0 0 0

Flexi HILOAD


Seat and Covers (A352-2A)

Parts List


1 42183.03 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 6211.08.030 Bolt - Hex Head 2 M8 x 306 6111.08.000 Nut - Plain 2 M87 42272.00 Headlight Guard 28 6210.08.016 Bolt - Dome Head 4 M8

9 5676.14.000 Beacon 1Also 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

16Fle

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

Parts List


Overhead Guard (A352-3A)

Parts List


1 41281.48 Battery Tank 1 check ballast23 40366.03 Battery Connection Bracket 14 6610.01.000 Bolt - Button Head 2 M6 x 125 6111.06.000 Nut - Plain 2 M66 - Cell 24 5HPzS-9307 55385.13.000 Battery Connection 18 6221.06.050 Setscrew - Cap Head 4 M6 x 509 6110.06.000 Washer - Flat 8 M6

10 6131.06.000 Nut - Nyloc 4 M6

Flexi HILOAD


Battery Tray Assembly (A352-4A)

fig. A352-4A: Battery Tray Assembly


- Ignition Switch 155523.01.005 Key Barrel 0

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

18Fle


Controls Assembly (A352-5A)

fig. A352-5A: Controls Assembly

Parts List

1

Flexi HILOAD

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

A353

HydraulicSystem

20Fle

Hydraulic System

Oil Tank Module (A353-1A)

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


1 41282.03 Oil Tank 1 Top profile - 41282-052 41282.01 Oil Tank Lid 1 Lift Motor3 41282.04 Oil Tank Lid 1 Steer Motor4 41282.02 Gasket 25 5454.02.000 Lift Pump Motor 1 See A353-1A-016 4981.03.000 Steering Pump 1 PLP20-8D7 55309.02.000 Steering Pump Motor 1 See A353-1A-028 44047.03.000 Lift Pump 1 PLP20-14S9 4004.01.000 Serrated Drive 2

10 4634.01.000 Suction Filter - Steering 111 4632.01.000 Suction Filter - Lift 1 1" BSP12 4959.01.000 Return Filter Assembly 113 4994.03.000 Cast Flanged Elbow 3 1/2" BSP14 4994.01.000 Cast Flanged Elbow 1 3/4" BSP15 4489.01.000 Connector 1 1" BSP - 1/2" BSP M/M16 4409.01.000 Connector - Male 2 3/4" BSP - -3/4" BSP M/M17 4466.01.000 Connector - Male 1 1" BSP - 3/4" BSP M/M18 4441.01.000 Connector - Male 2 1/2" BSP - 1/2" BSP M/M19 4452.01.000 Connector - Male 2 3/4" BSP - 1/2" BSP M/M20 4487.02.000 Connector - Three-Way Fitting 1 1/2" M - 1/2" F - 3/8" M+G2209 BSP21 - Connector 122 4976.01.000 Nylon Pipe 1 8mm diameter (/metre)23 4524.01.000 O-ring 1 1" BSP Dowty24 - Connector 125 3729.46 Hose 1 Steer Pump Suction26 3729.47 Hose 1 Lift Pump Suction27 3729.44 Steel Tube 1 Steer Pump Pressure28 3729.45 Steel Tube 1 Lift Pump Pressure29 3729.43 Oil Pipe 1 Steer Motor Bleed30 6221.08.035 Screw - Cap Head 16 M8 x 3531 6121.08.025 Screw - Socket Head 4 M8 x 2532 4520.01.000 O-ring 1 1/2" BSP Dowty33 6111.06.020 Setscrew 12 M6 x 20

34 6120.08.000 Washer - Spring 20 M835 6120.06.000 Washer - Spring 12 M636 4959.02.000 Return Filter 137 4959.03.000 Breather Filter 138 4959.12.000 Gasket 139 - Connector 140 5454.02.007 Carbon Brush 841 55309.02.003 Carbon Brush 442 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 4975.01.000 Male Stud Elbow Fitting 2 1/4" BSP - 8mm elbow

Flexi HILOAD


Parts List

Hydraulic System


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 1 016a 5454.02.000S Lift Motor Complete 1 Service Exchange

22Fle

Parts List

5454.02.004 Field Coil Kit 1 BM5-3005S

Hydraulic System


Lift Motor Module (A352-1A-00)

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

Ref TW Pt No NA Pt.No Description Qty NotesCost

(USD)Cost

(GBP)

1 - 55294.01.001 Drive Endhead 1 H95-003A2 - 55294.04.002 Bearing 1 BR-107 - 2.403 - 55294.04.003 Drive End Bearing Circlip 1 H-014 - -4 - 55294.04.004 Fan 1 A90-109C5 - 55309.02.001 Armature & Fan Assembly 1 BM5-31466 - 55309.02.002 Field Coil Kit 1 BM5-3005AS - -7 - 55309.02.003 Brush 4 A97-1012 - 10.648 - 5454.04.000 Brush Spring 4 B89-016 - 1.139 - 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 - 0.8812 - 55294.04.009 Washer - Wavy 1 H-01613 - 55309.02.005 Commutator Endhead 1 G97-102A14 - 55309.02.006 Headband Assembly 1 HB-1061 - 5.2715 - 55309.02.000 Steer Motor Complete 1 - 360.0715b - 55309.02.000S Steer Motor Complete 1 Service Exchange - 177.27

Flexi HILOAD

Not AvailableNot Available

Steer Motor Module (A353-1A-01)

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

Parts List

Not Available

Not AvailableNot Available

Hydraulic System


24Fle

Hydraulic System

Spool Valve Assembly (A353-2A)

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


1 4977.08.000 Spool Valve 12 41317.00 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 1 016 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 HILOAD

Spool Valve Assembly (A353-2A)

Parts List

7 Limit Switch XCM-A1022

Hydraulic System

26Fle

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 1 07 7647.11.000 Steering Wheel 1 ø 13"8 7646.06.000 Steering Column 1 09 - 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 1 013 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 1 029 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 1 033 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 2 040 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 1 052 55327.01.000 Reverse Horn 1 053 - Knob Steering Wheel 1 As part of Item # 754 7804.01.002 Signal Conditioning Module 1 055 42379.00 Rubber Clamp Pipe 1 056 6211.05.014 Bolt - Hex Head 2 M5 x 14 (Modify )57 7804.01.001 Steering Sensor 1 058 55508.06.000 Red LED Indicators 2 059 55508.07.000 Yellow LED Indicators 2 060 42315.00 Dashboard Fascia 1 061 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 2 065 - Plug 4 As part of item #6466 6111.10.040 Bolt - Hex Head 4 M10 x 40

Flexi HILOAD

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 42026.00 Sticker - Hill Start 18 41338.05 Steering Cowl 19 42315.00 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 HILOAD

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

Brake System

A354

Brake System


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 41297.10 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

30Fle

Brake System

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 0 Hub Rear Assembly 1 01 7738.08.000 Brake Cable 2 02 7738.08.002 Clip 2 03 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 41278.02 Rear Hub 2 7"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 2 012 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 7635.16.000 Tyre - Rear 2 Treaded Rubber 18" x 7"

Flexi HILOAD

Brake System

Rear Wheel Assembly (A354-2A)

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

Parts List

Brake System


1 - Brake Backplate R/H 1 01 - Brake Backplate L/H 1 02 7738.12.000 Adjuster 2 Manual3 7738.07.001 Cylinder - Wheel 2 04 - Common Shoe * 2 *5 7738.07.005 Tension Spring 4 06 7738.07.006 Tension Spring 2 07 7738.07.007 Spring 4 08 - Lefthand Shoe * 1 *8 - Righthand Shoe * 1 *9 7738.07.010 Bracket Spring 4 0

10 - Fixed Slice 4 011 6111.06.016 Bolt - Hex Head 4 M6 x 1612 6120.06.000 Washer - Spring 4 M613 7738.07.008 Bleed Nipple 2 014 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

32Fle

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

Parts List

Brake System

Brake Backplate Assembly (A354-3A)

Flexi HILOAD

Control System

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

34Fle

Electrical Module - Zapi Traction (A355-1B)

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

Control System


Flexi HILOAD

Control System



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

Ref TW Pt No NA Pt.No Description Qty Notes

00 B352924 - Zapi Controller Assembly 1 01 3004993 41283.03 Backplate 1 02 M1401-M6*30-25 6211.06.030 Bolt - Hex Head 6 M6 x 303 M1605-M6-2 6120.06.000 Washer - Spring 10 M64 M1602-M6-2 6110.06.000 Washer - Flat 10 M65 E1905017 55522.02.002 Traction Controller 1 AC3 Truck Serial No Required6 E3804001 55327.01.000 Audiable Alarm 1 Reverse Horn7 M1401-M6*16-25 6211.06.016 Bolt - Hex Head 10 M6 x 168 3004990 - Contactor Mounting Bracket 1 09 M1401-M5*12-25 6211.05.012 Bolt - Hex Head 2 M5 x 12

10 E0303033 C5188.04 Terminal Block 1 011 M1410-M4*16-25 6210.04.016 Screw - Button Head 2 M4 x 1612 E0303034 55522.02.005 Negative Terminal Post 1 013 M1410-M4*20-25 6210.04.020 Screw - Button Head 2 M4 x 2014 M1605-M4-2 6120.04.000 Washer - Spring 2 M415 M1602-M4-2 6110.04.000 Washer - Flat 2 M416 E4001044 55370.10.000 Relay Holder Blue 2 017 M1401-M3*30-25 6211.03.030 Bolt - Hex Head 4 M3 x 3018 M1501-M3-2 6111.03.000 Nut 4 M319 E0214003 5849.02.000 11-pin Relay 2 48V20 E0208009 55370.09.000 Timer Relay 2 021 E2802025 - Fuse Holder 3 022 M1410-M4*6-25 6210.04.006 Screw - Button Head 5 M4 x 623 E3101087 55097.04.000 Fuse 1 5A24 E3101067 55201.01.000 Fuse 2 10A25 3004991 - Fuse Holder Mounting Bracket 1 026 32211 - Washer - Flat 2 027 E4001120 55490.02.000 K4 Contactor 1 SW200-421 48V28 E4001122 55490.06.000 K6 Contactor 1 SW200-261 48V29 3004944 - Contactor Mounting Bracket 1 030 M1410-M5*8-25 6210.05.008 Screw - Button Head 4 M5 x 831 E3001040 55427.03.000 Load Resistor 1 120Ω 50W32 E2802002 55444.07.000 Fuse Holder 3 033 3004992A - Fuse Mounting Plate 1 034 E3101086 55096.01.000 Fuse 2 400A35 E3101085 5367.01.000 Fuse 1 100A36 E4001121 55490.01.000 K5 Contactor 1 SW80B-10 48V37 E1905017P01 - Cable Line 1 1 K4 to Fuse38 E1905017P02 - Cable Line 2 1 K6 to Fuse39 E1905017P03 - Cable Line 3 1 K5 to Fuse40 E1905017P04 - Cable Line 4 1 Fuse to Traction Contactor41 E1905017P05 - Cable Line 5 1 Traction Contactor to Negative Post42 E3401010 55450.01.000 Temperature Switch 1 043 M1401-M3*10-25 6211.03.010 Bolt - Hex Head 4 M3 x 1044 3005045 - K5 Label 1 045 3005044 - K4 Label 1 046 3005046 - K6 Label 1 047 3005047 - K9 Label 1 048 3005048 - K10 Label 1 049 M1605-M8-2 6120.08.000 Washer - Spring 5 M850 M1501-M8-20 6111.08.000 Nut 3 M851 3004994 6110.08.000 Washer - Flat 11 M852 M1602-M8-2 6110.08.000 Washer - Flat 5 M853 M1401049-25 6210.10.030 Bolt - Hex Head 1 M10 x 3054 M1501051-2 6111.10.000 Nut 3 M1055 E1905017P06 42090.01 Cable Line 6 1 056 M1410-M4*12-25 6210.04.012 Screw - Button Head 2 M4 x 1257a E4001011B - 48V Pin 1 0

55385.12.000 Battery Plug Female 1 Female Plug / Male Pins55385.13.000 Battery Plug Male 1 Male Plug / Female Pins55385.14.000 Battery Plug Handle 1 0

36Fle

Parts List

Control System


57b

Solenoid Switches (A355-1B-00)


1 55490.02.000 K4 Complete 1 Includes Items 2 - 122 - Top Cover 1 03 - Fixing Screws 2 04 - 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 1 09 - Plunger 1 See Item #12

10 - Coil & Magnet 1 011 - End Cap 1 012 55490.02.100 Contact Tip Kit 1 Includes; 4, 5, 6, 7, 9

13 55490.01.000 K5 Complete 1 Includes Items 14 - 2114 - Top Cover 1 015 - Fixing Screws 2 016 - Contact Fixtures 2 017 - 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

1 55490.06.000 K6 Complete 112 55490.06.100 Contact Tip Kit 1

Flexi HILOAD

Control System


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

Parts List

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

K5 Contactor - SW80B-10 - Steer Contact

K6 Contactor - SW200-261 - Steer ContactAs K4, except:

Reverse Alarm Kit (A355-1B-01)


00 0 0 0 01 55327.01.000 Audible Alarm 1 02 - Cables 2 03 6607.01.000 Screw - Taptite 2 M4 x 6 Taptite4 6621.01.000 Washer - Flat 2 05 6111.03.000 Nut - Plain 4 M30 0 0 0 0

38Fle

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

Parts List

Control System


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


1 55197.06.000 Fuse Terminal 1 02 55201.01.000 Fuse 10A 1 03 55415.01.000 Resistor 33Ω 100W 3 04 55209.01.000 Resistor 100Ω 50W 2 05 55427.09.000 Resistor 150Ω 25W 3 06 55468.02.000 Thermostat 1 RS159-20997 5940.01.000 SW80 24V Solenoid Switch 1 24V8 55115.01.000 Suppressor 1 0

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


00 5940.01.000 SW80 Complete 0 24V1 - Top Cover 1 02 - Fixing Screws 2 03 - 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 1 08 5618.01.000 Auxiliary Terminal Block 1 See Item #99 55490.01.100 Contact Tip Kit 1 Includes; 3, 4, 5, 6, 8

Flexi HILOAD

Parts List

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

Parts List

Control System

Wiring Looms (A355-2A)

40Fle

Control System

Wiring Looms (A355-2A)

fig. A355-2A: Truck Wiring Looms


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 HILOAD

Parts List

42

Flexi HILOAD

Mast System

Mast Support Assembly (A356-1A)

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

44Fle

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

Mast System

Mast Support Assembly (A356-1A)

Parts List


1 41249.16 Mast Support Fabrication 12 41424.01 Slewing Ring 13 6711.12.075 Set Pin - Hex Head 47 M12 x 75 Grade 10-94 7627.01.000 Thrust Washer 2 Glacier5 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 41249.24 Bearing Seat 1 Part of item #116 6120.16.000 Washer - Spring 4 M1617 6210.16.055 Screw - Button Head 4 M16 x 5518 41249.21 Articulation Shaft 119 - Spindle 120 6566.10.000 Grease Nipple 5 M1021 - Mast Support Clamp 1 Left, part of item #122 - Mast Support Clamp 2 Right, part of item #123 6591.01.000 Spring Clip 424 6110.24.000 Washer - Flat 4 M2425 44030.xx.000 Cylinder - Tilt 2 Check truck spec26 3526.03 Tilt Cylinder Mounting Shaft 4 027 4415.01.000 Connector 4 1/4" BSP - 1/4" BSP M/M28 4521.01.000 O-ring 8 1/4" BSP Dowty29 6211.14.065 Bolt - Hex Head 2 M14 x 6530 6111.14.000 Nut 2 M1431 - Connector 90 2 1/4" BSP - 1/4" BSP Elbow32 4415.01.000 Connector 2 1/4" BSP - 1/4" BSP M/M33 4439.01.000 Blanking Plug 2 1/4" BSP34 6211.05.014 Bolt - Hex Head 2 M5 x 1435 - Rubber Clamp Pipe 136 - Hose Fixed Seat 136 41896.01 Pivot Pin 1 Also see A352-1A-01

Flexi HILOAD

Mast System

Mast Assembly (A356-2A)


0 0 0 0 03912mm4521mm4800mm4928mm5550mm6600mm7410mm8400mm3912mm4521mm4800mm4928mm5550mm6600mm7410mm8400mm3912mm4521mm4800mm4928mm5550mm6600mm7410mm8400mm

0 0 0 0 0

46Fle

Mast System

Mast Fitting (A356-3A)

-Mast Sub-Assembly Third Stage(Inner)

13

2 -Mast Sub-Assembly Second Stage(Middle)

1

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

Parts List

1 -Mast Sub-Assembly Fixed Stage(Outer)

1


3912mm4050mm4200mm4521mm4620mm4800mm4928mm5010mm5220mm5400mm5550mm6000mm6210mm6600mm7020mm7200mm7410mm7620mm8010mm8204mm8220mm8400mm8610mm8820mm9000mm

Flexi HILOAD

Fixed Stage Assembly (A356-3A-01)

Mast System


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

Parts List

00 - Full Mast Assembly 1

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

48Fle

Fixed Stage Assembly (A356-3A-01)


Parts List (cont-)

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

Parts List

Mast System


6 41410.00 Cylinder Clamp 27 6121.10.045 Screw - Cap Head 4

2 4200mm0 5010mm0 5550mm0 6000mm0 6600mm0 7020mm0 7620mm0 8010mm0 8610mm0 9000mm

9 6353.01.000 Split Pin 410 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

55219.02.000 155219.03.000 1

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 120 6120.06.000 Washer - Spring 2 M6

0 4200mm0 5010mm0 5550mm0 6000mm

41404.xx 6600mm0 7020mm0 7620mm0 8010mm0 8610mm0 9000mm

22 6566.06.000 Grease Nipple - Angled 2 M6 45°23 4143.00 Manifold 124 6120.08.000 Washer - Spring 2 M825 6121.08.020 Screw - Cap Head 2 M8 x 20

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

28 6161.10.010 Grubscrew 2 M10 x 10 29 - - - -30 41396.xx Fixed Stage Mast Fabrication 1 Mast Ref number Required0 0 0 0

4200 045010 085550 016000 136600 167020 187620 218010 238610 269000 28

Flexi HILOAD

Second Stage Assembly (A356-3A-02)

For UK Masts replace .XX

LIFT HEIGHT .XX

Mast System


26 Shim n

27 Roller Assembly 4

15 Limit Switch

21Cylinder - Main Lift(Fixed Stage)

2

87694.01.000

(length as required)

Leaf Chain

- To Third Stage Mast, Lower

50Fle

Second Stage Assembly (A356-3A-02)

Mast System


Parts List

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



3 40558.03 Reaction Block 1 04 6131.06.025 Setscrew - Countersunk 2 M6 x 255 6150.30.000 Washer - Flat 2 M30 Light6 40149.00 Hose Pulley 2 07 40206.00 Bearing Spacer 3 08 40148.01 Chain Pulley 2 09 7672.01.000 Pulley Bearing 2 6306-2RS

10 6428.01.000 Circlip 2 72mm Internal11 3169.35.000 Spacer 1 012 41408.01 Hose Pulley 1 013 6150.30.000 Washer - Flat 1 M30 Light14 41409.00 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 HILOAD

Third Stage Assembly (A356-3A-03)


2 Roller Assembly 4

Mast System

1 Shim n

Ref TW Pt No UK Pt.No Description Qty Notes

1 31959 - Washer - Flat n M10 2t2 31483 7629.04.000 Rubber Buffer 2 03 M1602013 6110.10.000 Washer - Flat 2 M104 M1401-M10*35 6121.10.035 Screw - Cap Head 2 M10 x 35 5 M1401-M10*16 6111.10.016 Screw - Cap Head 2 M10 x 166 M1606-M10 6120.10.000 Washer - Spring 2 M107 30140A 41409.01 Pulley Shaft 2 2 0

52Fle

Third Stage Assembly (A356-3A-03)

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

Parts List

Mast System


Parts List (cont-)


4200mm5010mm5550mm6000mm6600mm7020mm7620mm8010mm8610mm9000mm

9 6353.01.000 Split Pin 8 010 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 41407.00 Chain Pulley 2 016 7672.01.000 Pulley Bearing 2 6306-2RS17 6428.01.000 Circlip 2 72mm Internal18 40206.02 Bearing Spacer 2 019 41408.00 Hose Pulley 2 020 6120.08.000 Washer - Spring 2 M821 6111.08.016 Setscrew 2 M8 x 16

0 4200mm0 5010mm0 5550mm0 6000mm0 6600mm

41405.xx 7020mm0 7620mm0 8010mm0 8610mm0 9000mm

23 6161.08.010 Grubscrew 2 M8 x 1024 41406.00 Pulley Yoke 2 025 6161.08.020 Grubscrew 4 M8 x 20


28 41410.01 Cylinder Clamp 2 029 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 HILOAD

Mast System

Narrow Aisle Fork Carriage Assembly (A356-4A)


22Cylinder - Free Lift(Third Stage)

2

26 Shim n

87694.01.000

(length as required)Leaf Chain 2


1 41411.xx Side-Shift 1 Bolzoni 860mm7671.01.000 Standard7773.01.000 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 0

6596.01.000 Standard 40 ID x 0-56596.03.000 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 1 016 4997.21.004 Upper Wear Pad - Left 1 017 4997.21.002 Lower Wear Pad - Right 1 018 4997.21.003 Lower Wear Pad - Left 1 019 4997.21.001 Cylinder - Side-shift 1 0

54Fle

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

Narrow Aisle Fork Carriage Assembly (A356-4A)

8 Shim n

Mast System

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

Parts List

2 Roller Assembly 4


0 0 0 0 01 - Mast Carriage Assembly 1 Kaup Standard Mast2 0000000000 Fork Carriage 1 Kaup Heavy Duty3 4997.44.023 Bush - Glacier 2 04 4997.44.025 Groove Ring 2 05 4997.44.022 Washer 2 06 4997.44.024 Stripper 2 07 4997.44.004 Piston Rod 2 08 4997.79.001 Holder 2 09 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 4997.44.00513a 4997.44.0614 4997.44.032 Grease Nipple 2 M815 6121.12.030 Stop Bolt 2 016 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 Standard7773.01.000 Heavy Duty

20 - Chain Anchor Assembly 2 00 0 0 0 0

Flexi HILOAD

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


Mast System

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

Parts List

Sliding Piece 4 13 or 13a


4200mm4620mm4800mm5010mm5400mm5550mm6000mm6210mm6600mm7020mm7200mm7410mm7620mm8010mm8220mm8400mm8610mm8820mm9000mm

56Fle

Mast System


Parts List (cont-)

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

Parts List

1See Note A(page 58)

Free Lift Feed Pipe 1

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.


0 4200mm0 4620mm0 4800mm0 5010mm0 5400mm0 5550mm0 6000mm0 6210mm0 6600mm

41441.xx 7020mm0 7200mm0 7410mm0 7620mm0 8010mm0 8220mm0 8400mm0 8610mm0 8820mm0 9000mm0 4200mm0 4620mm0 4800mm0 5010mm0 5400mm0 5550mm0 6000mm0 6210mm0 6600mm

41442.xx 7020mm0 7200mm0 7410mm0 7620mm0 8010mm0 8220mm0 8400mm0 8610mm0 8820mm0 9000mm


Flexi HILOAD

Mast System


Parts List (cont-)

3 Main Lift Feed Pipe 1

4See Note B(page 58)

Side-Shift Feed Pipe 1

2 Main Lift Feed Pipe 1



6 0 Manifold 1 Also see A356-3 Item #237 4971.05.000 Safety Valve 1 08 - Blanking Plug 1 09 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 1 017 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 M8

22 4245.03.000 Rupture Valve - Set to 1-2mm 23/8" Part of Free Lift Cylinder

23 6120.06.000 Washer - Spring 2 M624 - Spring 1 025 - O-ring 1 026 - Circlip 1 027 41437.00 Manifold 1 Also see A356-3 Item #2328 - Connector 1 029 - - - -30 - - - -31 - Plug 1 032 - Ring 1 0

33 44095.01.000Coned-stud Adapter(Not Shown)

1Required 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

58Fle

CAll four items required as NA equivelant to TW item #5

Mast System

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

0

AAll four items required as NA equivelant to TW item #1

BAll four items required as NA equivelant to TW item #4

14 41452.xxFree Lift Rubber Hose Assembly

1

15 41453.xxSide-Shift Rubber Hose Assembly

2

5See Note C

(below)Side-Shift Feed Pipe 1

Flexi HILOAD

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

Mast System

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

Parts List


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

5 44057.15.000 Bulkhead Coupling 3 8mm6 - Nut - Lock 4 0

5500mm6600mm7620mm8610mm

8 - Feed Pipe 1 09 - Rubber Hose 1 0

10 - Rubber Hose 1 011 44057.13.000 Bulkhead Coupling 2 15mm12 - Connector - Elbow 3 To A356-3-03 #2213 - Rubber Hose 2 014 - Connector - T 1 To A353-1A #19 & A356-3-03 #2215 - Pipe 1 8mm diameter16 - Connector - Elbow 3 017 - Pipe Clamp 2 018 - Nut 1 019 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

60Fle

4 41453.xx Side-Shift Hose - Primary 2

7 41452.xx Rubber Hose 1

2 41488.xx Side-shift Feed Pipe 1

3 41454.xx Side-Shift Hose - Secondary 2

1 41487.xx Side-shift Feed Pipe 1

Flexi HILOAD

A357

Accessory System

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

Accessory System

Labels (A357-1A)

62Fle

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

Accessory System

Labels (A357-1A)

fig. A357-1A-1: Labels


1 40222-36 Capacity Plate 1 Printed by Design Dept

2 40084-69 Warning Label 1 General Operation3 40084-00 Warning Label 2 Hand Crush _ Side force4 40084-01 Warning Label 2 Foot Crush - Side Force5 40084-70 Warning Label 1 Tip Over6 40084.04 Warning Label 2 Overhead Loads7 41344-?? Warning Label 1 Seat lift8 41431-?? Warning Label 1 Battery Retainers0 0 0 0 09 40084-12 Instruction Label 2 Lifting Points

10 40113-03 Instruction Label 1 Pedal functions11 40129-00 Instruction Label 1 Transmission Oil Fill Point12 40129-01 Instruction Label 1 Hydraulic Oil Fill Point13 40155-03 Instruction Label 1 Battery Charge Level14 7207-01-00 Instruction Label 1 Lifting Points15 41579-00 Instruction Label 4 Horn Symbol16 41930-00 Instruction Label 1 Light Symbol17 42026-00 Instruction Label 1 Hill-start Symbol

18 7618-09-000 Decal - Flexi logo 1 Set w/out flashes

19 40084-71 Instruction Label 1 Battery Charge Label

Flexi HILOAD

Seal Kit (A357-2A)

Parts List

fig. A357-1A-3: Label Locations 2

Parts List

Accessory System


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 4997.44.017Seal Kit - Sideshift Cylinder(for Alt Carriage Assembly)

2 Seal Kit A

6 4977.03.000 Seal Kit - Spool Valve Assebly 1 Seal Kit


1 3735-03 Axel Pivot Shaft 1 02 3526-05 Tilt Cylinder Mounting Shaft 4 03 - Cold Store Grease a/r Shell Alvania RA4 - Transmission Oil 0.8 Litre, Aral Degol PAS150

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

6 55413.03.000 Low Temperature 4 Core 6m Igus CF9.10.047 41715.01 Traction Motor Brush Cover 1 08 41715.02 Traction Motor Brush Cover 1 09 - Air Sentry 1 MP Filtri No. D-101

10 - Air Sentry Adaptors 2 MP Filtri No. A-10311 TB194 Technical Bulletin ref 0

64

Parts List

4 Seal Kit - Sideshift Cylinder 1

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

2 Seal Kit - Free Lift Cylinder 2

3 Seal Kit - Tilt Cylinder 2

1 Seal Kit - Main Lift Cylinder 2

A358

Index

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

exi HILOAD

1

allanallanallan

roved

3

exi HILOAD

5

exi HILOAD

7

9

exi HILOAD

11

exi HILOAD

13

exi HILOAD

15

exi HILOAD

17

exi HILOAD

19

exi HILOAD

21

exi HILOAD

Manitou(GBP)

-3.96

----

17.561.86

--

1.45--

8.70594.12292.50

23

exi HILOAD

25

exi HILOAD

27

29

exi HILOAD

31

exi HILOAD

33

exi HILOAD

35

exi HILOAD

37

exi HILOAD

39

exi HILOAD

41

43

exi HILOAD

45

exi HILOAD

47

exi HILOAD

49

exi HILOAD

51

exi HILOAD

53

exi HILOAD

55

exi HILOAD

57

exi HILOAD

59

exi HILOAD

61

exi HILOAD

63

65

Documents

FLEXI HILOAD Parts Manual - - Narrow Aisle Inc · 2019-11-20 · 7 4980.01.000 Hydraulic Steer Motor 1 Danfoss OMSW400 8 6120.12.000 Washer - Spring 8 M12 9 4975.06.000 Brass Straight