flexi-euro parts manual - narrow aisle inc · 2019-11-22 · 47 m0702052 4978.12.014 o-ring 1...

42238-00 Is0.00

Flexi-EUROParts Manual

Flexi Euro

2A350-1A - Document Revision Details 2

34

A351-2A - Axle and Transmission Assembly 6

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

A358 - Index 65A358-1A - By Part Name iA358-2A - By Part Reference Number - NA xiiiA358-3A - By Part Reference Number - TW xxiii

1Flexi Euro

Contents

A350 - Revisions

A351 - Transmission SystemA351-1A - Front Axle Assembly

Rev Date Revised By

A 04 / 03 / 2013 H ClemmetB 15 / 03 / 2013 H ClemmetC 05 / 06 / 2013 H ClemmetDEF

2

Revisions

Document Revision Details (A350-1A)

Description Approved

First Issue. P Callen20 items & 1 page (p47) added. P CallenFormatting corrected, A356 ammended P Callen

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Transmission System

A351

TransmissionSystem

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

p4p6

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Transmission System

Front Axle Assembly (A351-1A)

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

Transmission System

Ref TW Pt No NA Pt.No Description Qty Notes

00 B351465 7661.16.000 Front Wheel Assembly 2 Contains reference parts 1 & 201 B351440 4978.17.000 Transmission Assembly 1 See A351-2A, page 61 M1211080 7635.10.000 Tyre - Front 2 16.25 x 6 x 11.25 Plain Black2 35658 41218.02 Hub 23 35650A 41288.04 Axle Support Fabrication 14 35651A 41288.04.02 Mudguard (R) 1 Item 95 35652A 41288.04.02 Mudguard (L) 1 Item 106 35654A 41288.04.02 Crossbeam 1 Item 87 35666 41045.09 Front Counterweight 18 M0919-GE50ES 7644.01.000 Bearing 29 M1312-R75 6422.01.000 Circlip 2

10 M1423009 6121.20.060 Screw - Cap Head 2 M20 x 6011 M1402-M10*40 6121.10.040 Screw - Cap Head 4 M10 x 4012 M1401-M20*70 6211.20.070 Bolt - Hex Head 1 M20 x 7013 M1606-M20 6120.20.000 Washer - Spring 5 M2014 M1321001 6566.04.000 Grease Nipple 2 M1015 M1606-M24 6120.24.000 Washer - Spring 2 M2416 M1402-M20*140 6211.20.140 Bolt - Hex Head 4 M20 x 14017 M1401-M20*60 6111.20.060 Screw - Hex Head 1 M20 x 6018 3002772 42380.00 Terminal Mounting Plate 119 E0303031 55530.01.000 Terminal Block 120 M1602-M6 6110.06.000 Washer - Flat 2 M621 M1606-M6 6120.06.000 Washer - Spring 2 M622 M1402-M6*16 6121.06.016 Screw - Cap Head 2 M6 x 1623 M1602005 6110.08.000 Washer - Flat 2 M824 M1606-M8 6120.08.000 Washer - Spring 2 M825 M1424-M8*20 6121.08.020 Screw - Cap Head 2 M8 x 2026 3004375 42330.00 Cable Protection plate 127 M1606-M10 6120.10.000 Washer - Spring 2 M1028 M1423-M10*20 6121.10.020 Screw - Cap Head 2 M10 x 2029 55492-08-000 Traction Motor 1 AC - Schabmueller

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Front Axle Assembly (A351-1A)

Parts List

Transmission System

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Axle and Transmission Assembly (A351-2A)

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

Transmission System


00 B351440 4978.17.000 Transmission Assembly 1 Parts: All excluding 5101 B350605 - Differential Assembly 1 Parts: 10, 26, 27, 30, 31, 39, 40, 41, 54, 55 and 0202 B350568 - Differential Case 1 Parts: 28, 291 35678 300095 Front Tyre Base Axle 12 35682 30092 Gear Casing 13 30088A 30088 + 30094 Spacer 24 M1308-10*32 M1308.10*32 Key 1 10 x 8 x 325 30091A 30091 Cover Plate 26 M1424-M8*20 - Bolt 6 M8 x 207 M0909-30307 4978.15.002 Taper Roller Bearing 3 303078 30074 30074 Intermediate Gear 19 30073A 30073 Wheel-Helical 1

10 M0909-32013 7624.01.000 Taper Roller Bearing 6 3201311 30093F 30093 Gear Casing 2 112 M1301-16*20 M1301.16*20 Pin 2 16 x 2013 35677 30089 Connecting Shaft 114 M1301-16*40 M1301.16*40 Pin 4 16 x 4015 35680 30089 Front Tyre Base Axle 116 M0702053 4978.15.001 O-ring 2 TB80 x 105 x 13 (ACM)17 30085A 30085 Front Hub 218 30086 30086 Axle Screw 1219 M0801-AS234 - O-Ring 220 M1401-M10*30 6121.10.030 Screw - Cap Head 16 M10 x 3021 M1422002 M1422.CBS5.8 Screw - Cap Head 6 CBS5-822 M1301-10*30 M1301.10*30 Pin 4 10 x 3023 30083A 30083 Nut - Lock 224 30084A 30084 Nut - Lock 225 35681 30079 Front Axle-Long 126 M1424004 M1401.M10*30 Bolt - Hex Head 1227 32098 31502017 Differential Gear 228 30082B 30082 Differential Case 1 M10 x P1-25 x 3029 30081B 30081 Differential Case 130 32096 32502009 Washer - Flat 231 M1424-M8*65 M1402.M8*65 Bolt - Hex Head 12 M8 x 6532 35679 30078 Front Axle-Short 133 M0909-32009 4978.15.004 Taper Roller Bearing 1 3200934 30076A 4978.15.010 Input Pinion-Helical 135 30071 30071 Spacer 136 - - - - -37 30075 30075 Helical Gear 138 31594 92502010 Breather 239 32104 32502015 Differential Gear 440 32102 32502014 Differential Washer 441 32100 30080 Differential Spider 142 M1424007 - Bolt 643 M0604008 92502010 Screw Plug 1 Breather44 30296 4978.15.018 Washer 145 30297 - Washer 1

M1423008 6111.10.030 Bolt - Hex Head 7 M10 x 30M1402-M10*25 6211.10.025 Bolt - Hex Head 1 M10 x 25

47 M0702052 4978.12.014 O-ring 1 Output shaft seal ø42 x ø72 x 8mm48 M0604005 - Bung 249 M1424009 - Bolt 550 30087 4978.15.005 Nut - Wheel 1251 55492-08-000 Traction Motor 1 AC - Schabmueller52 30094 4978.15.017 Shim 253 M1602-M10 6110.10.000 Washer - Flat 8 M1054 M1605-M10 6120.10.000 Washer - Spring 39 M1055 M1605-M8 6120.08.000 Washer - Spring 18 M8

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Axle and Transmission Assembly (A351-2A)

Parts List

46

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Chassis Fitting System

Chassis Kit (A352-1A)

A352

Chassis FittingSystem

A352-1A - Chassis Kit ..................................................................... A352-1A-00 - Steering Motor Extension ............................... A352-1A-01 - Additional Chassis Parts .................................A352-2A - Seat and Covers ............................................................A352-3A - Overhead Guard ............................................................A352-4A - Battery Tray Assembly ...................................................A352-5A - Controls Assembly .........................................................

p10p12p13p14p16p17p18

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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 35667E 41265.22 Chassis Fabrication 1 Narrow Chassis

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

42181.01 1 Left-hand42181.02 1 Right-hand

2 M1602028 6110.12.000 Washer - Flat 4 M123 M1605-M12 6120.12.000 Washer - Spring 6 M124 M1424-M12*40 6211.12.040 Bolt - Hex Head 8 M12 x 405 30262B 41328.02 Quarter Ballast 1 Left Hand Side6 34898 6453.01.000 Roll Pin 27 35940A 41328.01 Quarter Ballast 1 Right Hand Side8 M1606-M20 6120.20.000 Washer - Spring 10 M209 M1401-M20*50 6121.20.050 Screw - Cap Head 2 M20 x 50

10 30372 7093.01.000 Brass Tee Piece 111 M1606-M6 6120.06.000 Washer - Spring 4 M612 M1401-M6*40 6121.06.040 Screw - Cap Head 1 M6 x 4013 35892A 42091.01 Brake Pipe 1 R/H Wheel to Tee14 35893A 42091.02 Brake Pipe 1 L/H Wheel to Tee15 30375A 6581.05.000 Brake Pipe 1 Tee to Brake Master Cylinder16 M0609001 6517.02.000 Hole Insert 6 Side Ballast ø42mm17 30250B 41345.00 Battery Plug Bracket 118 M1602-M8 6120.08.000 Washer - Spring 4 M819 M1401-M8*25 6121.08.025 Screw - Cap Head 8 M8 x 2520 30260C 41320.02 Side Ballast 1 Left Hand Side21 E3805010 55131.14.000 Fan 2 48 Volt22 M1602-M4 6110.04.000 Washer - Flat 8 M423 M1401-M4*45 6121.04.045 Screw - Cap Head 8 M4 x 4524 30261C 41320.01 Side Ballast 1 Right Hand Side25 M1401-M20*70 6121.20.070 Screw - Cap Head 8 M20 x 7026 3001163 - Anti-Slip Plate Left 127 3001167 - Anti-Slip Plate Right 128 30290 41318 Electrical Mounting Bracket 129 M1423-M10*30 6111.10.030 Bolt 2 M10 x 3030 M1606-M10 6120.10.000 Washer - Spring 2 M10

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Parts List

1d - Lower Step Plate


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

10 M0601016 4443.01.000 Connector - Male 2 1/2" - 3/8" BSP (to Steer Lock Valve)11 M0801015 4520.01.000 Seal 2 1/2" BSP Dowty12 35894 - Tee Connector 113 M0511001 4976.01.000 Nylon Pipe 2 Steer Motor Extension Bleed (/metre)

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Steering Motor Extension (A352-1A-00)

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

Parts List



Additional Chassis Parts (A352-1A-01)


1 35667E 41265.22 Chassis Fabrication 1 Narrow Chassis2 - 41577.00 Battery Retaining Assembly 1

2a 30115C 41577.01 Battery Tank Fixed Support 1 Part of item 22b 30116D 41577.02 Buckle Board 1 Part of item 22c 30117 41577.03 Pin 1 Part of item 23 M1307006 6355.01.001 Split Pin 2 Battery Retainer4 M1606-M10 6120.10.000 Washer - Spring 2 M105 M1401-M10*25 6121.10.025 Setscrew - Cap Head 2 M10 x 256 M1606-M8 6120.08.000 Washer - Spring 4 M87 M1424-M8*25 6111.08.025 Setscrew - Hex Head 2 M8 x 258 M1602-M8 6110.08.000 Washer - Flat 4 M89 M1410-M4*25 - Bolt - Button Head 4 M4 x 25

10 M1602-M4 6110.04.000 Washer - Flat 4 M411 M1606-M4 6120.04.000 Washer - Spring 5 M4

12 3608236083 42032.0242032.03 Battery Lid Bracket 11Right-handLeft-hand

13 M2002002 7763.01.000 Extension Spring 2 12 O/D x 1-5 Wire x 35 F/L14 M1501-M10 41316.00 Nut - Dome Face 2 M1015 M1423-M12*60 6211.12.060 Bolt - Hex Head 2 M12 x 6016 35404 6110.12.000 Washer - Flat 8 M1217a 30292B Handbrake Cable Linkage 1 Set Reference 41302-1217b 30293B Handbrake Cable Linkage 117c 30299 Handbrake Cable Linkage 118 M0920-LFB1215 7626.10.000 Bush - Glacier 2 PM1215 DX19 M1501-M12 6111.12.000 Nut - Plain 2 M1220 M1606-M12 6120.12.000 Washer - Spring 6 M1221 M1501-M4 6111.04.000 Nut - Plain 4 M4

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Parts List


Seat and Covers (A352-2A)

41302.30

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

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


Seat and Covers (A352-2A)

Parts List


1 35723 41339.02 Battery Lid 12 3002940 41337.05 Front Electronics Cover 13 - - - - -4 35724 41385.01 Seat Pan 15 35726 41336.05 Front Nose Cone Cover 16 30618A 7659.01.000 Gas Strut 1 650N7 35522B 42046.00 Seat Wire Plate 1 Protects Seat Switch Cable8 30389A 55497.01.000 Document Holder 19 M1323040 7633.27.000 Seat 1 MSG 20 inc- Belt (PVC)

10 35653A 41321.08 Floor Plate 111 M1409-M6*12 6131.06.012 Bolt - Countersunk 4 M6 x 1212 M1401-M8*30 6221.08.030 Bolt - Cap Head 5 M8 x 3013 M1502-M8 6131.08.000 Nut - Nyloc 5 M814 M1323071 7598.05.000 Latch 2 For Battery Lid15 M1602-M10 6110.10.000 Washer - Flat 4 M1016 35657D 41372.11 Seat Frame 117 M1401-M10*40 6121.10.040 Screw - Cap Head 4 M10 x 4018 M1401-M5*12 6610.01.000 Screw - Button Head 4 M5 x 1219 M0507002 4976.01.000 Nylon Pipe 1 8mm diameter ( /metre)20 30171A 41394.00 Seat Stop 121 M1401-M10*25 6600.01.000 Screw - Pozi Pan 2 M10 x 25 Taptite22 M1602013 6110.10.000 Washer - Flat 4 M1023 M1323138 7307.01.000 Edging Strip 1 ( /metre) 24 - - - - -25 M1602010 6110.08.000 Washer - Flat 7 M826 - - - - -27 - - - - -28 M1503-M6 6131.06.000 Nut - Nyloc 2 M629 M1606-M8 6120.08.000 Washer - Spring 4 M830 30789P08A 7703.03.000 Rubber Buffer 231 31446 7703.03.000 Rubber Buffer 232 M1602-M6 6110.06.000 Washer - Flat 2 M633 M1401-M6*20 6121.06.020 Screw - Cap Head 234 32750 7633.27.005 Seat Runners 235 E3720003 - Pipe Connector 136 M1323016 41372.02 Seat Frame Support 337 M1323015 7703.03.000 Seat Frame Buffer 338 33904 41944.00 Hose Protection Funnel 139 - - - - -40 - 42350 Seat Latch 1 Includes 40a, Striker Plate41 - - - - -42 - - - - -43 - - - - -44 M1410-M5*10 6121.05.010 Bolt - Dome Head 2 M5 x 1045 3003629 41394.00 Seat Stop Plate 146 - - - - -47 - - - - -48 M1401-M4*50 6211.04.050 Bolt - Hex Head 4 M4 x 5049 E3805010 55131.14.000 Fan 1 48 Volt50 M1503-M4-2 6112.04.000 Nut - Plain 4 M4

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Overhead Guard (A352-3A)

Parts List



1 - 42183.06 Overhead Guard 12 M1423039 6171.14.045 Bolt - Durlock 8 M14 x 453 M1606-M14 6120.14.000 Washer - Spring 8 M144 E2302004 5306.06.000 Headlight 2 24V, 48V5 M1401-M8*30 6211.08.030 Bolt - Hex Head 2 M8 x 306 M1501-M8 6111.08.000 Nut - Plain 27 - 42272.00 Headlight Guard 28 - 6210.08.016 Bolt - Dome Head 4 M89 E2302073 5676.14.000 Beacon 1 Also see 5676-10-000 (Beacon) and 5676-11-000 (Guard)

10 M1401-M6*20 6211.06.020 Bolt - Hex Head 3 M6 x 2011 M1501-M6 6131.06.000 Nut - Nyloc 312 M1323039 7404.02.000 Rear View Mirror 113 M1409-M5*10 6121.05.010 Screw - Cap Head 2 M5 x 1014 M1614004 6110.05.000 Washer - Flat 1 M5

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

Parts List


Battery Tray Assembly (A352-4A)

Parts List


1 - 41369.27 Battery Tank 12 30418A - Support Leg 1 Part of 41369-103 35664A 40366.03 Battery Connection Bracket 14 M1410-M6*12 6610.01.000 Bolt - Button Head 2 M6 x 125 M1503-M5 6111.05.000 Nut - Plain 2 M56 E3801031 - Cell 24 4HPzS-6207 - 55385.13.000 Battery Connection 18 M1401-M6*50 6221.06.050 Setscrew - Cap Head 4 M6 x 509 M1602-M6 6110.06.000 Washer - Flat 8 M6

10 M1501-M6 6131.06.000 Nut - Nyloc 4 M6

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Controls Assembly (A352-5A)

fig. A352-4A: Battery Tray Assembly



E1302030 - Ignition Switch- 55523.01.005 Key Barrel

2 E1202014 55498.01.000 Horn Switch 13 E0901017 7633.19.001 Seat Switch 14 35659B 41340.12 Spool Valve Lever Cover 15 M1329-M6 6549.01.000 Jack Nut 4 M46 E1608007 55519.02.000 Headlight Switch 1 55520-02-000 for switch base7 M1410-M6*20 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 30620A 7620.02.000 Handbrake Assembly 1 See List A353-2A

18

fig. A352-5A: Controls Assembly

Parts List

1 1

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Hydraulic System

Oil Tank Module (A353-1A)

A353

HydraulicSystem

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

p20p22p23p24p26p28

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

Hydraulic System


Parts List


1 35660B 41282.23 Oil Tank 1 Top profile - 41282-222 35661A 41282.01 Oil Tank Lid 1 Lift Motor3 35662A 41282.04 Oil Tank Lid 1 Steer Motor4 30206 41282.02 Gasket 25 E2102002 5454.02.000 Lift Pump Motor 1 See A353-1A-016 3000816 4981.03.000 Steering Pump 1 PLP20-8D7 E2102003 55309.02.000 Steering Pump Motor 1 See A353-1A-028 3000815 44047.03.000 Lift Pump 1 PLP20-14S9 30623 4004.01.000 Serrated Drive 2

10 M0303002 4634.01.000 Suction Filter - Steering 111 M0303003 4632.01.000 Suction Filter - Lift 1 1" BSP12 M0303004 4959.01.000 Return Filter Assembly 113 30614 4994.03.000 Cast Flanged Elbow 3 1/2" BSP14 30615 4994.01.000 Cast Flanged Elbow 1 3/4" BSP15 35458 4489.01.000 Connector 1 1" BSP - 1/2" BSP M/M16 M0601007 4409.01.000 Connector - Male 2 3/4" BSP - -3/4" BSP M/M17 M0601008 4466.01.000 Connector - Male 1 1" BSP - 3/4" BSP M/M18 M0601009 4441.01.000 Connector - Male 2 1/2" BSP - 1/2" BSP M/M19 M0601010 4452.01.000 Connector - Male 2 3/4" BSP - 1/2" BSP M/M20 35467 4487.02.000 Connector - Three-Way Fitting 1 1/2" M - 1/2" F - 3/8" M+G2209 BSP21 35895 - Connector 122 M0507002 4976.01.000 Nylon Pipe 1 8mm diameter (/metre)23 M1613006 4524.01.000 O-ring 1 1" BSP Dowty24 35470 - Connector 125 30344A 3729.46 Hose 1 Steer Pump Suction26 30345 3729.47 Hose 1 Lift Pump Suction27 31790A 3729.44 Steel Tube 1 Steer Pump Pressure28 35735A 3729.45 Steel Tube 1 Lift Pump Pressure29 34818 3729.43 Oil Pipe 1 Steer Motor Bleed30 M1401-M8*35 6221.08.035 Screw - Cap Head 16 M8 x 3531 M1424-M8*25 6121.08.025 Screw - Socket Head 4 M8 x 2532 M1613005 4520.01.000 O-ring 1 1/2" BSP Dowty33 M1423-M6*20 6111.06.020 Setscrew 12 M6 x 20

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

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Lift Motor Module (A352-1A-00)

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 116a - 5454.02.000S Lift Motor Complete 1 Service Exchange

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

Parts List

- 5454.02.004 Field Coil Kit 1 BM5-3005S


Steer Motor Module (A353-1A-01)

Hydraulic System


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

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

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

Parts List

Hydraulic System

Spool Valve Assembly (A353-2A)

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

Hydraulic System

Spool Valve Assembly (A353-2A)

Parts List


1 M0302039 4977.08.000 Spool Valve 12 35656C 41317.01 Spool Valve Mounting Bracket 13 30620A 7620.02.000 Handbrake Assembly 14 M0302004 4970.03.000 Flow Regulator 25 M0302005 4667.01.000 Hold Valve 1 48V6 36008 - Spacer 1

55219.02.000 155219.03.000 1

8 3004347 7668.01.000 Handbrake Cable 19 30284A 41348.08 Lever 1 1 Side-shift

10 30283A 41348.07 Lever 2 1 Tilt11 30282A 41348.06 Lever 3 1 Lift12 30554 7638.07.000 Lever Knobs 1 Side-shift13 30571 7638.06.000 Lever Knobs 1 Tilt14 30570 7638.05.000 Lever Knobs 1 Lift15 - 41391.00 Retaining Strap 116 35907 - Bolt 1 Handbrake17 M1401-M10*35 6121.10.035 Screw - Cap Head 1 M10 x 35 (cut down)18 M1401-M10*20 6221.10.020 Screw - Cap Head 1 M10 x 2019 35454A 4813.01.000 Connector 2 1/4" - 3/8" BSP M/M20 M1401-M4*25 6601.01.000 Screw - Cap Head 4 M4 x 25 Taptite21 M0605001 4437.01.000 Blanking Plug 1 1/2" BSP22 M1613004 4520.01.000 O-ring 4 1/2" Dowty23 35456 4441.02.000 Coupler M0601021 4 1/2" - 1/2" BSP M/M24 35460A - Spacer 225 M0501079 (3729.82) Rubber Hose 126 M0501078 (3729.87) Rubber Hose 127 M0501077 (3729.86) Rubber Hose 128 M0501080 (3729.84) Rubber Hose 129 M0501397 (3729.83) Rubber Hose 130 M0501400 (3729.34) Rubber Hose 1 S/S Restrictor - Mast31 M0501398 (3729.12) Rubber Hose 1 S/S Spool - Mast32 M0501399 (3729.85) Rubber Hose 133 M0501401 (3729.60) Rubber Hose 1

34 M0501402 (3729.61) Rubber Hose 135 M1401-M8*55 6221.08.055 Screw - Cap Head 3 M8 x 5536 M1606-M8 6120.08.000 Washer - Spring 3 M837 M1401-M6*40 6111.06.040 Screw - Cap Head 2 M6 x 4038 M0302009 - Solenoid 139 35461B - Connector 1 To Item #3440 M1613002 4521.01.000 O-ring 4 1/4" BSP Dowty41 M1613003 4522.01.000 O-ring 4 3/8" BSP Dowty42 35461B - Connector 1 To Item #3343 35464 4914.02.000 Adjustable Elbow 1 1/2" BSP44 - - - - -45 M1602031 - Washer - Flat 1 Dowty46 M1602-M10 6110.10.000 Washer - Flat 2 M1047 M1606-M10 6120.10.000 Washer - Spring 2 M1048 M1423008 6111.10.030 Bolt - Hex Head 2 M10 x 3049 - - - - -50 - 4977.08.001 Spool Valve Lever Housing 3

25Flexi Euro

7 E0901002P03 Limit Switch XCM-A1022

Hydraulic System

Steering Column Module (A353-3A)

26Flexi Euro


Parts List

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

Hydraulic System


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 M1503001 - Nut 17 39537 7647.11.000 Steering Wheel 1 ø 13"8 3005368 7646.06.000 Steering Column 19 302309 - Steering Wheel Cover 1 As part of Item # 7

10 - - Label 1 See A357-1A11 M1606-M10 6120.10.000 Washer - Spring 10 M1012 35665B 41285.02 Steering Column Support 113 M1602028 6110.12.000 Washer - Flat 1 M1214 M1423040 41365.00 Hinge Screw 2 M12 x 2515 M1602-M12 6110.12.000 Washer - Flat 2 M1216 M1423-M10*30 6111.10.030 Bolt - Hex Head 2 M10 x 3017 M1317017 7601.01.000 Adjustable Hand Lever 1 Locking Lever18 E3601035 55481.01.003 Zapi Display Unit 1 Panel Kit19 35455 4443.01.000 Connector 4 1/2" BSP - 3/8" BSP M/M20 M0801-AS908 4520.01.000 O-ring 4 1/2" BSP Dowty21 M0501303 (3729.101) Rubber Hose 1 Orbital / Lock Valve22 M0501304 (3729.100) Rubber Hose 1 Orbital / Lock Valve23 M0501066 (3729.107) Rubber Hose 1 Priority Valve / Orbital24 M0501067 (3729.105) Rubber Hose 1 Orbital / Tank Filter25 M0501068 (3729.102) Rubber Hose 1 Lock Valve / Steer Motor26 M0501305 (3729.103) Rubber Hose 1 Lock Valve / Steer Motor27 35693 44001.09.000 Steel Orbital Valve 1 100cc28 35655B 41242.09 Steering Column Mount 129 M1423-M10*25 6111.10.025 Setscrew - Hex Head 4 M10 x 2530 35457 4472.01.000 Connector 4 3/8" BSP - 3/8" BSP M/M31 M1613003 4522.01.000 O-ring 5 3/8" BSP Dowty32 M0302003 4973.01.000 Steering Lock Valve 133 M1602-M8 6110.08.000 Washer - Flat 2 M8

34 M1401-M8*90 6121.08.090 Screw - Cap Head 2 M8 x 9035 M0501306 (3729.108) Rubber Hose 1 Lock Valve / Tank36 E1605009 5202.04.000 Direction Lever 137 E3001007 5400.01.000 Resistor 2 Paired with Item #5038 M1613002 4521.01.000 O-ring 3 1/4" BSP Dowty39 30168P04 - Steel Tube 240 E3804010 5300.02.000 Horn 1 24V41 30168 - Swivel Hose Bracket Assembly 1 Mounting Bracket42 30169B - Swivel Hose Bracket Assembly 1 Lower Swivel Bracket43 30170C - Swivel Hose Bracket Assembly 1 Upper Swivel Bracket44 M1401-M10*100 6121.10.100 Screw - Cap Head 2 M10 x 10045 M1503-M10 6131.10.000 Nut - Nyloc 2 M1046 M1503-M12 6131.12.000 Nut - Nyloc 1 M1247 M0410004 C65983.01 Pressure Test Point 1 1/4" BSP48 35463 4914.03.000 Adjustable Elbow 1 3/8" BSP - 3/8" BSP49 M1323138 7307.01.000 Edging Strip 2 (/metre) 50 E3003004 5400.01.000 Diode 1 Paired with Item #3751 E1622001 55498.02.000 Hill Start Switch 152 - - - - -53 32442 - Knob Steering Wheel 1 As part of Item # 754 E3811135 7804.01.002 Signal Conditioning Module 155 3003273 42379.00 Rubber Clamp Pipe 156 M1410-M5*14-23 6211.05.014 Bolt - Hex Head 2 M5 x 14 (Modify )57 E3811136 7804.01.001 Steering Sensor 158 E2301011 55508.06.000 Red LED Indicators 259 E2301012 55508.07.000 Yellow LED Indicators 260 3003371 42315.00 Dashboard Fascia 161 3002942A 41338.06 Steering Cowl 162 35032A 41378.00 Cowl Reinforcement 1 Part of Item #6163 M1401-M8*35 6121.08.035 Screw - Cap Head 4 M8 x 3564 M1317014 7598.04.000 Handle 265 M0609003 - Plug 4 As part of item #6466 M1423010 6111.10.040 Bolt - Hex Head 4 M10 x 40

27Flexi Euro

Hydraulic System


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


1 E2301012 55508.07.000 Yellow LED Indicator 2 02 E2301011 55508.06.000 Red LED Indicator 2 03 E3601035 55481.01.003 Electronic Display 1 04 M1401-M8*35 6121.08.035 Screw - Cap Head 4 M8 x 355 M1317014 7598.04.000 Handle 2 06 E1622001 55498.02.000 Hill Start Switch 1 07 34957 42026.00 Sticker 1 Hill Start8 3002942A 41338.06 Upper Steering Cowl 1 09 3003371 42315.00 Dashboard Fascia 1 0

28

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

Parts List

29Flexi Euro

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

p30p31p32

Brake System

A354

Brake System

Pedal Plate Module (A354-1A)


1 35663 41297.04 Pedal Mounting Plate 12 E1905006P01 55481.01.001 Accelerator Pedal Unit 1 Part of Traction Panel Kit3 - - Accelerator Rubber 14 34952 41296.03 Brake Pedal 15 34939 55215.07.000 Brake Pedal Rubber 16 35000 41291.01 Brake Push Rod 17 34915 7197.04.000 Brake Master Cylinder 18 E0901036 CA829802 Micro Switch 1 Traction Cut-out9 32776 7081.01.000 Expansion Spring 1

10 35328 41297.10 Cable Guard 111 M0920-LFB1215 7625.01.000 Bush - Glacier 212 M1401-M6*20 6121.06.020 Screw - Cap Head 2 M6 x 2013 M1401-M8*25 6121.08.025 Screw - Cap Head 2 M8 x 2514 M1401-M8*35 6221.08.035 Screw - Cap Head 1 M8 x 3515 M1602-M8 6110.08.000 Washer - Flat 3 M816 M1503-M8 6131.08.000 Nut - Nyloc 4 M817 M1401-M10*20 6111.10.020 Screw - Setscrew 2 M10 x 2018 M1606-M10 6120.10.000 Washer - Spring 2 M1019 M1401-M12*30 6221.12.030 Screw - Cap Head 1 M12 x 3020 M1401-M12*90 6211.12.090 Bolt - Hex Head 1 M12 x 9021 M1501-M12 6111.12.000 Nut - Plain 1 M1222 M1503-M12 6131.12.000 Nut - Nyloc 1 M1223 M1501017 6114.02.000 Nut - Plain 1 5/16" UNF

30Flexi Euro

Rear Wheel Assembly (A354-2A)

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

Parts List

Brake System


00 B350555A 7738.11.000 Brake Back Plate Assembly 1 Lefthand; See A354-3A00 B350556A 7738.10.000 Brake Back Plate Assembly 1 Righthand; See A354-3A01 B350602 - Hub Rear Assembly 11 30315 7738.08.000 Brake Cable 22 33884 7738.08.002 Clip 23 M1321-M6 6566.06.000 Grease Nipple - Angled 2 M6 45°4 31997A 6171.14.040 Bolt - Durlock 12 M14 x 405 M0706001 4998.01.000 O-ring 2 ø75 x ø105 x 13mm6 M0909-32013X/Q 7624.01.000 Taper Roller Bearing 2 320137 30237D 41278.00 Rear Hub 2 6"8 M0909-32010X/Q 7624.02.000 Taper Roller Bearing 2 32010 50 x 80 x 209 30227 4998.06.000 Nut - Lock 2 M45 x 1-5mm

10 30240 4998.07.000 Washer - Lock 2 MB9 45mm11 30238C 41293.00 Grease Cover 212 M1606-M6 6120.06.000 Washer - Spring 12 M613 M1409-M6*12 6121.06.012 Screw - Button Head 12 M6 x 12

14 M1409-M6*12 6131.06.012Screw - Countersunk Socket Head

6 M6 x 12

15 M1211003 7635.09.000 Tyre - Rear 2 Plain Rubber 18" x 6"

31Flexi Euro

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

Parts List

Brake System

Brake Backplate Assembly (A354-3A)


1 30612F - Brake Backplate R/H 11 30612F - Brake Backplate L/H 1

7738.12.000 Manual0 0

3 30604 7738.07.001 Cylinder - Wheel 24 30607 - Common Shoe * 25 30608A 7738.07.005 Tension Spring 46 30609B 7738.07.006 Tension Spring 27 30610A 7738.07.007 Spring 48 30606 - Lefthand Shoe * 18 30611 - Righthand Shoe * 19 34509A 7738.07.010 Bracket Spring 4

10 34631 - Fixed Slice 411 M1424-M6*16 6111.06.016 Bolt - Hex Head 4 M6 x 1612 M1606-M6 6120.06.000 Washer - Spring 4 M613 - 7738.07.008 Bleed Nipple 214 M1424-M12*25 6111.12.025 Setscrew - Hex Head 2 M12 x 2515 - 7738.07.012 Nordlock Washer 2 M12

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

32

2

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

Parts List

2 B350630B Adjuster

33Flexi Euro

A355

Control System

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

p34p37p38p39p39p40

Control System

Electrical Module - Zapi Traction (A355-1B)

34Flexi Euro

Control System


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

35Flexi Euro

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

Control System


Parts List


00 B352924 - Zapi Controller Assembly 11 3004993 41283.03 Backplate 12 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 19 M1401-M5*12-25 6211.05.012 Bolt - Hex Head 2 M5 x 12

10 E0303033 C5188.04 Terminal Block 111 M1410-M4*16-25 6210.04.016 Screw - Button Head 2 M4 x 1612 E0303034 55522.02.005 Negative Terminal Post 113 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 217 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 221 E2802025 - Fuse Holder 322 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 126 32211 - Washer - Flat 227 E4001120 55490.02.000 K4 Contactor 1 SW200-421 48V28 E4001122 55490.06.000 K6 Contactor 1 SW200-261 48V29 3004944 - Contactor Mounting Bracket 130 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 333 3004992A - Fuse Mounting Plate 134 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 143 M1401-M3*10-25 6211.03.010 Bolt - Hex Head 4 M3 x 1044 3005045 - K5 Label 145 3005044 - K4 Label 146 3005046 - K6 Label 147 3005047 - K9 Label 148 3005048 - K10 Label 149 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 6 156 M1410-M4*12-25 6210.04.012 Screw - Button Head 2 M4 x 1257a E4001011B - 48V Pin 1

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

55385.14.000 Battery Plug Handle 1

36Flexi Euro

Solenoid Switches (A355-1B-00)


Control System


K4 Contactor - SW200-421 - Bypass / Hydraulic Lift Contact1 E4001120 55490.02.000 K4 Complete 1 Includes Items 2 - 122 - - Top Cover 13 - - Fixing Screws 24 - - Contact Fixtures 2 See Item #125 - - Return Spring 1 See Item #126 - - Fixed Contact 2 See Item #127 - - Moving Contact 1 See Item #128 - - Top Cover Base 19 - - Plunger 1 See Item #12

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

K5 Contactor - SW80B-10 - Steer Contact13 E4001121 55490.01.000 K5 Complete 1 Includes Items 14 - 2114 - - Top Cover 115 - - Fixing Screws 216 - - Contact Fixtures 217 - - Return Spring 1 See Item #2118 - - Fixed Contact 2 See Item #2119 - - Moving Contact 1 See Item #2120 - - Coil & Magnet 1 See Item #2121 - 55490.01.100 Contact Tip Kit 1 Includes; 17, 18, 19, 20

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

1 E4001122 55490.06.000 K6 Complete 112 - 55490.06.100 Contact Tip Kit 1

37Flexi Euro

Reverse Alarm Kit (A355-1B-01)

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

Parts List

Control System



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

38Flexi Euro

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


Parts List

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

Parts List

Control System


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

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


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

39Flexi Euro

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

Parts List

Control System

Wiring Looms (A355-2A)

40Flexi Euro

Wiring Looms (A355-2A)

Parts List

fig. A355-2A: Truck Wiring Looms

Control System


1 - 42090.00 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

41Flexi Euro

43Flexi Euro

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 ..................................... A356-3A-03 - Third Stage Assembly .........................................A356-4A - Narrow Aisle Fork Carriage Assembly ………………................. A356-4A-00 - Alternative Fork Carriage Assembly .......................A356-5A - Narrow Aisle Hydraulic Components Fixed Stage …..................A356-6A - Narrow Aisle Hydraulic Components Third Stage ......................

p44p46p47p48p50p52p54p55p56p59

Mast System

Mast Support Assembly (A356-1A)

44Flexi Euro

Mast System

Mast Support Assembly (A356-1A)

Parts List

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


1 35668D 41249.09 Mast Support Fabrication 12 B350598A 41424.01 Slewing Ring 13 M1402004 6711.12.075 Set Pin - Hex Head 47 M12 x 75 Grade 10-94 35669A 41249.26 Mast Support Clamp 2 Right, part of item #15 M1401-M20*90 6221.20.090 Screw - Cap Head 4 M20 x 906 M1606-M20 6120.20.000 Washer - Spring 4 M207 M1321001 6566.04.000 Grease Nipple 2 M108 M0920-LFB5040 7626.01.000 Bush - Glacier 2 Mast9 30105 41343.01 Mast Retaining Washer 2

10 M1606-M10 6120.10.000 Washer - Spring 2 M1011 M1401-M10*30 6121.10.030 Screw - Cap Head 2 M10 x 3012 M1410-M6*20 6612.01.000 Screw - Button Head 4 M6 x 2013 30338 7629.03.000 Rubber Buffer 214 M1312-S50 6588.01.000 Circlip 115 M1307007 6591.01.000 Spring Clip 416 30109A 6110.24.000 Washer - Flat 4 M2417 30155C 44030.xx.000 Cylinder - Tilt 218 30110E 3526.03 Tilt Cylinder Mounting Shaft 419 35465 4415.01.000 Connector 4 1/4" BSP - 1/4" BSP M/M20 30103F - Spindle 121 M0801-AS906 4521.01.000 O-ring 8 1/4" BSP Dowty22 M1423006 6211.14.065 Bolt - Hex Head 2 M14 x 6523 M1501014 6111.14.000 Nut 2 M1424 35002 7627.01.000 Thrust Washer 2 Glacier25 35466 - Connector 90 2 1/4" BSP - 1/4" BSP Elbow26 32437 4415.01.000 Connector 2 1/4" BSP - 1/4" BSP M/M27 35473 4439.01.000 Blanking Plug 2 1/4" BSP28 35276B 41249.24 Bearing Seat 1 Part of item #129 35288C 41249.21 Articulation Shaft 130 M1606-M16 6120.16.000 Washer - Spring 4 M1631 M1401-M16*55 6210.16.055 Screw - Button Head 4 M16 x 5532 35670 41249.25 Mast Support Clamp 1 Left, part of item #133 M1321-M10 6566.10.000 Grease Nipple 5 M1034 M1410-M5*14-23 6211.05.014 Bolt - Hex Head 2 M5 x 1435 3001737 - Rubber Clamp Pipe 136 3003557 - Hose Fixed Seat 1

45Flexi Euro

Mast System

Mast Assembly (A356-2A)


31190 4800mm30157E 5550mm30770B 6600mm30771B 7410mm30158A 8400mm31191 4800mm30173 5550mm30776 6600mm30777 7410mm30159 8400mm31192 4800mm30185 5550mm30782 6600mm30783 7410mm30160 8400mm

46Flexi Euro

1 -Mast Sub-Assembly Fixed Stage(Outer)

1

Mast Sub-Assembly Second Stage(Middle)

1

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

Parts List

Mast System

3 -Mast Sub-Assembly Third Stage(Inner)

1

2 -

Mast Fitting (A356-3A)


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

47Flexi Euro

Fixed Stage Assembly (A356-3A-01)

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

Parts List

00 - Full Mast Assembly 1

Mast System



1 31959 - Washer - Flat n M10 2t2 31447 7629.04.000 Rubber Buffer 23 M1602013 6110.10.000 Washer - Flat 2 M104 M1401-M10*40 6121.10.040 Screw - Cap Head 2 M10 x 40 5 M1501-M10 6131.10.000 Nut - Nyloc 4 M10

48Flexi Euro

Fixed Stage Assembly (A356-3A-01)

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

Parts List

Mast System


Parts List (cont-)


6 30141A 41410.00 Cylinder Clamp 27 M1401-M10*45 6121.10.045 Screw - Cap Head 4

M1204023 4200mmM1204028 5010mmM1204030 5550mmM1204032 6000mmM1204036 6600mmM1204038 7020mmM1204043 7620mmM1204045 8010mmM1204047 8610mmM1204048 9000mm

9 M1307002 6353.01.000 Split Pin 410 30340A 7694.03.000 Chain Anchor Pin 2 8234-0911 30153A 7694.02.000 Chain Anchor Bolt 2 BL0534 MB112 M1501-M16 6111.16.000 Nut - Plain 2 M1613 M1503-M16 6131.16.000 Nut - Nyloc 2 M1614 30151B 40558.06 Limit Switch Bracket 1

55219.02.000 155219.03.000 1

16 M1401-M4*16 6121.04.016 Screw - Cap Head 2 M4 x 1617 M1606-M6 6120.06.000 Washer - Spring 2 M618 M1423-M6*10 6610.01.000 Screw - Button Head 4 M6 x 1019 30359 41451.11 Bulkhead Bracket 120 M1605-M6 6120.06.000 Washer - Spring 2 M6

B350564 4200mmB350762 5010mmB350569 5550mmB350684 6000mmB350571 41404.xx 6600mmB350758 7020mmB350573 7620mmB350760 8010mmB350581 9000mm

22 M1321-M6 6566.06.000 Grease Nipple - Angled 2 M6 45°23 30143B 4143.00 Manifold 124 M1605-M8 6120.08.000 Washer - Spring 2 M825 M1424-M8*20 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 M1403-M10*10 6161.10.010 Grubscrew 2 M10 x 10 29 - - - - -30 - 41396.xx Fixed Stage Mast Fabrication 1

4200 045010 085550 016000 136600 167020 187620 218010 238610 269000 28

49Flexi Euro

Second Stage Assembly (A356-3A-02)

Leaf Chain

- To Third Stage Mast, Lower2

15 E0901002P01 Limit Switch 0

87694.01.000

(length as required)

21Cylinder - Main Lift(Fixed Stage)

2

26 30162A Shim n

Mast System


27 30161 Roller Assembly 4

For UK Masts replace .XX

LIFT HEIGHT .XX

50Flexi Euro

Second Stage Assembly (A356-3A-02)

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

Mast System


Parts List



3 30154A 40558.03 Reaction Block 14 M1409-M6*25 6131.06.025 Setscrew - Countersunk 2 M6 x 255 30165 6150.30.000 Washer - Flat 2 M30 Light6 30144 40149.00 Hose Pulley 27 30166 40206.00 Bearing Spacer 38 30138A 40148.01 Chain Pulley 29 M0901-6306ZZ 7672.01.000 Pulley Bearing 2 6306-2RS

10 M1312-R72 6428.01.000 Circlip 2 72mm Internal11 30167A 3169.35.000 Spacer 112 30149A 41408.01 Hose Pulley 113 30164A 6150.30.000 Washer - Flat 1 M30 Light14 30139A 41409.00 Pulley Shaft 1 2 30 OD x 112 BSP15 M1606-M8 6120.08.000 Washer - Spring 2 M816 M1402-M8*16 6111.08.016 Setscrew 2 M8 x 1617 - 0 Second Stage Mast Fabrication 1

51Flexi Euro

Third Stage Assembly (A356-3A-03)


1 30162A Shim n

Mast System



1 31959 - Washer - Flat n M10 2t2 31483 7629.04.000 Rubber Buffer 23 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

52Flexi Euro

Third Stage Assembly (A356-3A-03)

Parts List

Mast System


Parts List (cont-)

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


M1204053 4200mmM1204029 5010mmM1204031 5550mmM1204033 6000mmM1204037 6600mmM1204039 7020mmM1204044 7620mmM1204022 8010mmM1204028 8610mmM1204049 9000mm

9 M1307002 6353.01.000 Split Pin 810 30340A 7694.03.000 Chain Anchor Pin 4 8234-0911 30153A 7694.02.000 Chain Anchor Bolt 4 BL0534 MB112 M1501-M16 6111.16.000 Nut - Plain 4 M1613 M1503-M16 6131.16.000 Nut - Nyloc 4 M1614 30164A 6150.30.000 Washer - Flat 2 M30 Light15 30147A 41407.00 Chain Pulley 216 M0901-6306ZZ 7672.01.000 Pulley Bearing 2 6306-2RS17 M1312-R72 6428.01.000 Circlip 2 72mm Internal18 30166 40206.02 Bearing Spacer 219 30149A 41408.00 Hose Pulley 220 M1606-M8 6120.08.000 Washer - Spring 2 M821 M1424-M8*16 6111.08.016 Setscrew 2 M8 x 16

B350565A 4200mmB350763A 5010mmB350583A 5550mmB350685A 6000mmB350585A 6600mmB350759A 41405.xx 7020mmB350587A 7620mmB350761A 8010mmB350589A 8610mmB350595A 9000mm

23 M1403-M8*10 6161.08.010 Grubscrew 2 M8 x 1024 30146B 41406.00 Pulley Yoke 225 M1403-M8*20 6161.08.020 Grubscrew 4 M8 x 20


28 30142 41410.01 Cylinder Clamp 229 M1503-M8 6131.08.000 Nut - Nyloc 4 M830 30165 6150.30.000 Washer - Flat 4 M30 Light31 - 0 Third Stage Mast Fabrication 1

Flexi Euro

87694.01.000

(length as required)Leaf Chain 2

22Cylinder - Free Lift(Third Stage)

2

26 30162A Shim n


Mast System

Narrow Aisle Fork Carriage Assembly (A356-4A)


1 35634 41411.xx Side-Shift 1 Bolzoni 860mm7671.01.000 Standard7773.01.000 Heavy Duty

3 30153A 7694.02.000 Chain Anchor Bolt 2 BL 0534 MB14 30340A 7694.03.000 Chain Anchor Pin 2 8234-095 M1501-M16 6111.16.000 Nut - Plain 2 M166 M1503-M16 6131.16.000 Nut - Nyloc 2 M167 M1307002 6353.01.000 Split Pin 2

6596.01.000 Standard 40 ID x 0-56596.03.000 Heavy Duty

9 36030 41936.03 Fork 2 1150 mm10 M1321-M6 6566.06.000 Grease Nipple 4 M611 M1402-M16*25 6121.16.025 Screw - Cap Head 1 M16 x 2512 M1606-M16 6120.16.000 Washer - Spring 1 M1613 M1402-M8*12 6121.08.012 Screw - Cap Head 1 M8 x 1214 M1606-M8 6120.08.000 Washer - Spring 1 M815 - 4997.21.005 Upper Wear Pad - Right 116 - 4997.21.004 Upper Wear Pad - Left 117 - 4997.21.002 Lower Wear Pad - Right 118 - 4997.21.003 Lower Wear Pad - Left 119 - 4997.21.001 Cylinder - Side-shift 1

54Flexi Euro

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

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

Parts List


8 30162A Shim n

Mast System

Narrow Aisle Fork Carriage Assembly (A356-4A)


1 1512660025 - Mast Carriage Assembly 1 Kaup Standard Mast2 1512660026 0 Fork Carriage 13 210084501 4997.44.023 Bush - Glacier 24 20320020 4997.44.025 Groove Ring 25 1510945701 4997.44.022 Washer 26 30320601 4997.44.024 Stripper 27 430999701 4997.44.004 Piston Rod 28 1512949501 4997.79.001 Holder 29 9460162808 6121.12.060 Screw 2 M16 x 6010 1510950801 4997.44.019 Guide Roller 211 9310300005 4997.44.035 Nut 4 M3012 8770080101 4997.44.033 Grease Nipple 2 M813 4997.44.00513a 4997.44.0614 8770080001 4997.44.032 Grease Nipple 2 M815 4190990101 6121.12.030 Stop Bolt 216 M1606-M16 6120.16.000 Washer - Spring 1 M1617 M1402-M16*25 6121.16.025 Screw - Cap Head 1 M16 x 2518 - 41936.03 Fork 2

7671.01.000 Standard7773.01.000 Heavy Duty

20 - - Chain Anchor Assembly 2

55Flexi Euro

Parts List

210035401 Sliding Piece 4 13 or 13a

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

19 30161

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

Mast System

4Roller Assembly


34893 4200mm34884 4620mm35038 4800mm34890 5010mm35102 5400mm30350 5550mm34887 6000mm35069 6210mm30355 6600mm34881 7020mm34878 7200mm30358 7410mm34977 7620mm34870 8010mm35066 8220mm30364 8400mm34992 8610mm35118 8820mm35035 9000mm

56Flexi Euro

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

Parts List

Mast System


Parts List (cont-)

1See Note A(page 58)

Free Lift Feed Pipe 1

Important:- All masts are stamped either NA or TW, please state when ordering parts.- For all masts stamped with TW, please see item number 33, page 58.


30308 4200mm30308 4620mm30308 4800mm30308 5010mm30308 5400mm30308 5550mm30310 6000mm30310 6210mm30310 6600mm30310 41441.xx 7020mm30310 7200mm30310 7410mm30310 7620mm30310 8010mm30310 8220mm35209 8400mm35209 8610mm35209 8820mm35209 9000mm30309 4200mm30309 4620mm30309 4800mm30309 5010mm30309 5400mm30309 5550mm30311 6000mm30311 6210mm30311 6600mm30311 41442.xx 7020mm30311 7200mm30311 7410mm30311 7620mm30311 8010mm30311 8220mm35210 8400mm35210 8610mm35210 8820mm35210 9000mm34891 4200mm34882 4620mm35132 4800mm34888 5010mm35100 5400mm30353 5550mm34885 6000mm35067 6210mm30356 6600mm34879 7020mm34874 7200mm30362 7410mm34975 7620mm34868 8010mm35064 8220mm30367 8400mm35097 8610mm35116 8820mm35033 9000mm

57Flexi Euro

4See Note B(page 58)

Side-Shift Feed Pipe 1

2 Main Lift Feed Pipe 1

3 Main Lift Feed Pipe 1

Mast System


Parts List (cont-)


34892 4200mm34883 4620mm35133 4800mm34889 5010mm35101 5400mm30354 5550mm34886 6000mm35068 6210mm30357 6600mm34880 7020mm34877 7200mm30363 7410mm34976 7620mm34869 8010mm35065 8220mm30368 8400mm35098 8610mm35117 8820mm35034 9000mm

6 B350599 0 Manifold 1 Also see A356-3 Item #237 30756P01B 4971.05.000 Safety Valve 18 30756P02A - Blanking Plug 19 30172 4627.04.000 Pipe Clamp 3 8mm Twin

10 M0601016 44057.12.000 Connector - Male 2 1/2" BSP - 15mm11 35477 44057.13.000 Bulkhead Coupling 1 15mm12 M0601022 44057.14.000 Connector - Male 4 3/8" BSP - 10mm13 35482 44057.15.000 Connector 2 8mm

M0502007 5500mmM0502008 6600mmM0502009 7620mmM0502010 8610mmM0501086 5500mm Also seeM0501093 6600mm A356-6M0501096 7620mm Item #4M0501100 8610mm

16 30359 41451.11 Bulkhead Bracket 117 M1315047 4627.05.000 Pipe Clamp 4 15mm Single18 M1424-M8*20 6111.08.020 Setscrew 2 M8 x 2019 M1410-M5*12 6610.01.000 Screw - Button Head 3 M5 x 1220 M1423-M6*16 6111.06.016 Bolt - Hex Head 2 M6 x 1621 M1605-M8 6120.08.000 Washer - Spring 2 M8

22 33639 4245.03.000 Rupture Valve - Set to 1-2mm 2 3/8" Part of Free Lift Cylinder

23 M1605-M6 6120.06.000 Washer - Spring 2 M624 30756P04A - Spring 125 M0801012 - O-ring 126 M1312-R13 - Circlip 127 30143B 41437.00 Manifold 1 Also see A356-3 Item #2328 35472 - Connector 129 - - - - -30 - - - - -31 M0604001 - Plug 132 30756P03 - Ring 1

33 - 44095.01.000Coned-stud Adapter(Not Shown)

1 Required to connect a mast stamped with TW to an NA truck chassis ONLY.

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

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

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

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

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

41486.xx Sideshift Feed Pipe 1

58Flexi Euro

5See Note C

(below)Side-Shift Feed Pipe 1

15Side-Shift Rubber Hose Assembly

2

14Free Lift Rubber Hose Assembly

1

A See Item #1All four items required as NA equivelant to TW item #1

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

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

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

Mast System

41453.xx

41452.xx

59Flexi Euro

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

Mast System

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

Parts List


M0501083 5500mmM0501090 6600mmM0501094 7620mmM0501097 8610mmM0501084 5500mmM0501091 6600mmM0501095 7620mmM0501098 8610mmM0501085 5500mmM0501092 6600mmM0501096 7620mmM0501099 8610mmM0501086 5500mm Also SeeM0501093 6600mm A356-5M0501097 7610mm Item #15M0501100 8610mm

5 35481 44057.15.000 Bulkhead Coupling 3 8mm6 M1501010 - Nut - Lock 4

M0502007 5500mmM0502008 6600mmM0502009 7620mmM0502010 8610mm

8 35476 - Feed Pipe 19 M0501087 - Rubber Hose 1

10 M0501088 - Rubber Hose 111 35477 44057.13.000 Bulkhead Coupling 2 15mm12 35478 - Connector - Elbow 3 To A356-3-03 #2213 M0501089 - Rubber Hose 214 30379 - Connector - T 1 To A353-1A #19 & A356-3-03 #2215 30370 - Pipe 1 8mm diameter16 35479 - Connector - Elbow 317 33885 - Pipe Clamp 218 M1501009 - Nut 119 M0801-AS906 4521.01.000 O-ring 2 1/4" BSP Dowty20 M0507002 4976.01.000 Nylon Pipe 1 8mm diameter (/metre)21 - - - - -22 M1424-M8*16 6211.08.016 Bolt - Hex Head 2 M8 x 1623 M1605-M8 6120.08.000 Washer - Spring 2 M8

60

1

1 41487.xx Side-shift Feed Pipe 1

2

3 41454.xx Side-Shift Hose - Secondary 2

2 41488.xx Side-shift Feed Pipe

7 41452.xx Rubber Hose 1

4 41453.xx Side-Shift Hose - Primary

61Flexi Euro

Accessory System

Labels (A357-1A)

A357

Accessory System

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

p62p64p64

62Flexi Euro

fig. A357-1A-1: Labels

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

Accessory System

Labels (A357-1A)


1 0 40222-36 Capacity Plate 1 Printed by Design Dept0

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

9 0 40084-12 Instruction Label 2 Lifting Points10 0 40113-03 Instruction Label 1 Pedal functions11 0 40129-00 Instruction Label 1 Transmission Oil Fill Point12 0 40129-01 Instruction Label 1 Hydraulic Oil Fill Point13 0 40155-03 Instruction Label 1 Battery Charge Level14 0 7207-01-00 Instruction Label 1 Lifting Points15 0 41579-00 Instruction Label 4 Horn Symbol16 0 41930-00 Instruction Label 1 Light Symbol17 0 42026-00 Instruction Label 1 Hill-start Symbol

18 0 7618-09-000 Decal - Flexi logo 1 Set w/out flashes

19 0 40084-71 Instruction Label 1 Battery Charge Label

63Flexi Euro

Seal Kit (A357-2A)

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

Parts List

Accessory System

Parts List


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

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

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

2 Seal Kit A

6 - 4977.03.000 Seal Kit - Spool Valve Assebly 1


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

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

64

1 B350738 Seal Kit - Main Lift Cylinder 2

Parts List

Seal Kit - Free Lift Cylinder

4 B350802 Seal Kit - Sideshift Cylinder 1

B350739

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

Seal Kit - Tilt Cylinder 2

2

3 B350740

2

65

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

A358

Index

flexi-euro parts manual - narrow aisle inc · 2019-11-22 · 47 m0702052 4978.12.014 o-ring 1...

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