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

42407-00 Issue C

FLEXI HIMAXParts Manual

2A350-1A - Document Revision Details 2

3A351-1A - Front Axle Assembly 4A351-2A - 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 43

A356-1A - Mast Support Assembly 44A356-3A-01 - Fixed Stage Assembly 46A356-3A-02 - Second Stage Assembly 48A356-3A-03 - Third Stage Assembly 50

A356-5A - Narrow Aisle Hydraulic Components - Fixed Stage 52A356-6A - Narrow Aisle Hydraulic Components - Third Stage 54A356-7A - Narrow Aisle Hydraulic Components - Tilting Carriage 56

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

Flexi Himax

Contents

A350 - Revisions

A351 - Transmission System

Rev Date Revised By

A 17 / 05 / 2013 H ClemmetB 04 / 06 / 2013 H ClemmetC 26/ 07 / 2013 R. BennettD

2F

Update P Ca

First Issue P CaTilting Carriage Revision P Ca

Revisions

Document Revision Details (A350-1A)

Description Appro

Transmission System

A351

TransmissionSystem

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

4F

Transmission System

Front Axle Assembly (A351-1A)

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

Transmission System

Ref TW Pt No NA Pt.No Description Qty Notes

00 B350686 7661.09.000 Front Wheel Assembly 2 Contains reference parts 1 & 201 B350603 4978.15.000 Transmission Assembly 1 See A351-2A, page 61 M1211080 7635.14.000 Tyre - Front 2 16.25 x 7 x 11.25 Plain Black2 30106C 41218.00 Hub 23 - 41288.03 Axle Support Fabrication 14 30107A - Pin 1 To join items 3 & 75 30108.00 - Washer 1 M86 30102B 41288.04.02 Crossbeam 17 - 41045.08 Front Counterweight 18 M0919-GE50ES 7644.01.000 Bearing 29 M1312-R75 6422.01.000 Circlip 2

10 M1401-M20*60 6121.20.060 Screw - Socket Cap Head 1 M20 x 6011 M1602011 - Washer 1 M1012 M1401-M20*70 6211.20.070 Bolt - Hex Head 1 M20 x 7013 M1606-M20 6120.20.000 Washer - Spring 5 M2014 M1321001 6566.04.000 Grease Nipple 2 M1015 M1606-M24 6120.24.000 Washer - Spring 1 M2416 M1402-M20*140 6211.20.140 Bolt - Hex Head 4 M20 x 14017 - 6111.24.100 Screw - Hex Head 2 M24 x 10018 3002772.00 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 3004375.00 42330.00 Cable Protection plate 127 M1606-M10 6120.10.000 Washer - Spring 3 M1028 M1423-M10*20 6121.10.020 Screw - Cap Head 2 M10 x 2029 55492-08-000 Traction Motor 1 AC Schabmueller30 30114P03 - Axle Clamp 231 M1401-M10*20 6121.10.020 Screw - Cap Head 1 M10 x 2032 M1606-M8 6120.08.000 Washer - Spring 1 M833 M1401-M8*20 6121.08.020 Screw - Cap Head 1 M8 x 2034 - 4978.15.005 Wheel Nut 12

Flexi Himax

Transmission System

Front Axle Assembly (A351-1A)

Parts List

6F

Axle and Transmission Assembly (A351-2A)

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

Transmission System


00 B350603 4978.15.000 Transmission Assembly 1 Parts: All excluding 51

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

02 B350568 - Differential Case 1 Parts: 28, 291 30095B 300095 Front Tyre Base Axle 12 30092E 30092 Gear Casing 13 30088A 30088 + 30094 Spacer 24 M1328-10*32 M1308.10*32 Key 1 10 x 8 x 325 30091A 30091 Cover Plate 26 M1424-M8*20 - Bolt 6 M8 x 207 M0909-30307 4978.15.002 Taper Roller Bearing 3 303078 30074 30074 Intermediate Gear 19 30073A 30073 Wheel-Helical 1

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

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

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

Flexi Himax

46

Axle and Transmission Assembly (A351-2A)

Parts List

Flexi Himax

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

10F

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 - 41265.25 Chassis Fabrication 1 Pallet Truck Batt. Removal

1a - 41277.05 Stub Axle 21b - - Leg Guards 21c 34946.00 - 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 34898.00 6453.01.000 Roll Pin 27 30263C 41328.01 Quarter Ballast 1 Right Hand Side8 M1606-M20 6120.20.000 Washer - Spring 10 M209 M1401-M20*50 6121.20.050 Screw - Cap Head 2 M20 x 50

10 30372.00 7093.01.000 Brass Tee Piece 111 M1606-M6 6120.06.000 Washer - Spring 4 M612 M1401-M6*40 6121.06.040 Screw - Cap Head 1 M6 x 4013 30373A 6581.03.000 Brake Pipe 1 R/H Wheel to Tee14 30374A 6581.04.000 Brake Pipe 1 L/H Wheel to Tee15 30375A 6581.05.000 Brake Pipe 1 Tee to Brake Master Cylinder16 3005090.00 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 E3805003 55131.14.000 Fan 2 48 Volt22 M1602-M4 6110.04.000 Washer - Flat 8 M423 M1401-M4*45 6121.04.045 Screw - Cap Head 8 M4 x 4524 30261C 41320.01 Side Ballast 1 Right Hand Side25 M1401-M20*70 6121.20.070 Screw - Cap Head 8 M20 x 7026 3001163.00 - Anti-Slip Plate Left 127 3001167.00 - Anti-Slip Plate Right 128 30290.00 41318.00 Electrical Mounting Bracket 129 M1423-M10*30 6111.10.030 Bolt 2 M10 x 3030 M1606-M10 6120.10.000 Washer - Spring 2 M1031 - 41286.00 Steer Motor Mounting Plate 132 - 4690.01.000 Pipe Clip (not shown) 2 1/4"

Flexi Himax


Lower Step Plate


Parts List

1d -


1 M1401-M12*40 6121.12.040 Screw - Cap Head 8 M12 x 402 M1501-M12 6111.12.000 Nut - Plain 8 M123 30077F 41535.00 Steer Pinion Shaft 14 M0901-6210ZZ 7735.01.000 Bearing 2 6210-2RSI ø90 x ø20 x 50mm5 30419B 41536.01 Bearing Housing 1 To suit Danfoss6 M1312-S50 6588.01.000 Circlip 1 M507 M0305006 4980.01.000 Hydraulic Steer Motor 1 Danfoss OMSW4008 M1606-M12 6120.12.000 Washer - Spring 8 M129 35943.00 4975.06.000 Brass Straight Fitting 1 1/4" BSP - 8mm T

10 35455.00 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 35894.00 - Tee Connector 113 M0511001 4976.01.000 Nylon Pipe 2 Steer Motor Extension Bleed (/metre)

12F




Steering Motor Extension (A352-1A-00)

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

Parts List

Additional Chassis Parts (A352-1A-01)


1 - 41265.25 Chassis Fabrication 1 Pallet Truck Batt. Removal2 - 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 30117.00 41577.03 Pin 1 Part of item 23 - 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 M1401-M8*25 6111.08.025 Setscrew - Hex Head 2 M8 x 258 M1602-M8 6110.08.000 Washer - Flat 4 M89 - 6610.01.000 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 34949A34950A 42032.0242032.03 Battery Lid Bracket 2Right-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 35404.00 6110.12.000 Washer - Flat 8 M1217a 30292B Handbrake Cable Linkage 1 Set Reference 41302-1217b 30293B Handbrake Cable Linkage 117c 30299.00 Handbrake Cable Linkage 118 M0920-LFB1215 7626.10.000 Bush - Glacier 2 PM1215 DX19 M1501-M12 6111.12.000 Nut - Plain 2 M1220 M1605-M12 6120.12.000 Washer - Spring 6 M1221 M1501-M4 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 plate 1 Also sold as a set - 41896.0025 - 44078.01.000 Roller bearing 1 160 x 75 x 37 mm26 - 41896.03 Seal Retainer Plate 1 Also sold as a set - 41896.00

Flexi Himax

41302.30

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

Parts List


Seat and Covers (A352-2A)

14F

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


Seat and Covers (A352-2A)

Parts List


1 - 41339.03 Battery Lid 12 3002938B 41337.10 Front Electronics Cover 13 M1323041 41390.00 Arm Rest Cushion 14 30264C 41385.00 Seat Pan 15 0.00 41336.04 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 34947C 41321.06 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 30789I 41372.00 Seat Frame 117 M1401-M10*40 6121.10.040 Screw - Cap Head 2 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 30281.00 41342.00 Direction Lever Cover 125 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 3005223.00 41372.02 Rubber Buffer 331 31446.00 7703.03.000 Rubber Buffer 332 M1602-M6 6110.06.000 Washer - Flat 2 M633 M1401-M6*20 6121.06.020 Screw - Cap Head 234 32750.00 7633.27.005 Seat Runners 235 E3720003 - Pipe Connector 136 M1323016 - Seat Frame Support 1 Contains 1 x #30 & 1 x #3137 M1323015 - Seat Frame Buffer 1 Contains 1 x #30 & 1 x #3138 33904.00 41944.00 Hose Protection Funnel 139 - - - - -40 - 42350.00 Seat Latch 1 Includes 40a, Striker Plate41 - - - - -42 - - - - -43 - - - - -44 M1410-M5*10 6121.05.010 Bolt - Dome Head 2 M5 x 1045 3003629.00 41394.00 Seat Stop Plate 146 - - - - -47 - - - - -48 M1401-M4*50 6211.04.050 Bolt - Hex Head 4 M4 x 5049 E3805003 55131.14.000 Fan 2 48 Volt50 M1503-M4-2 6112.04.000 Nut - Plain 4 M4

Flexi Himax

Overhead Guard (A352-3A)

Parts List



1 - 42183.05 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 2 M87 - 42272.00 Headlight Guard 28 - 6210.08.016 Bolt - Dome Head 4 M8

9E2302073 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 3 M612 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

16F

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

Parts List


Battery Tray Assembly (A352-4A)

Parts List


1 - 41369.31 Battery Tank 12 30418 - Support Leg 1 Part of 41369-103 35664 40366.03 Battery Connection Bracket 14 M1410-M6*12 6610.01.000 Bolt - Button Head 2 M6 x 125 M1503-M6 6111.06.000 Nut - Plain 2 M66 E3801008 - Cell 24 6HPzS-9307 - 55385.13.000 Battery Connection 18 M1401-M6*50 6221.06.050 Setscrew - Cap Head 4 M6 x 509 M1602-M6 6110.06.000 Washer - Flat 8 M6

10 M1501-M6 6131.06.000 Nut - Nyloc 4 M6

Flexi Himax

fig. A352-4A: Battery Tray Assembly


Controls Assembly (A352-5A)


E1302030 - Ignition Switch- 55523.01.005 Key Barrel

2 E1605009 5202.04.000 Direction Lever 13 E0901017 7633.19.001 Seat Switch 14 30280E 41340.00 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 A353-2A12 E1202014 55498.01.000 Horn Switch 1

18

fig. A352-5A: Controls Assembly

Parts List

11

Flexi Himax

A353

HydraulicSystem

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

Hydraulic System

Oil Tank Module (A353-1A)

20F

Hydraulic System


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


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

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

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

Flexi Himax

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

22F


Steer Motor Module (A353-1A-01)

Hydraulic System

- 5454.02.004 Field Coil Kit 1 BM5-3005S

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

Parts List

Lift Motor Module (A352-1A-00)


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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Hydraulic System

Spool Valve Assembly (A353-2A)

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

Parts List

24F

Hydraulic System

Spool Valve Assembly (A353-2A)

Parts List

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


1 M0302039 4977.08.000 Spool Valve 12 30279B 41317.00 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 E0901007P02 5277.01.000 Spool Valve Micro Switch 2

55219.02.000 155219.03.000 1

8 30316 7668.01.000 Handbrake Cable 19 30284B 41348.08 Lever 1 1 Side-shift

10 30283B 41348.07 Lever 2 1 Tilt11 30282B 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 41393.00 Bolt - Hex Head 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 6 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 (3729.6) 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 3002425 0.00 Spacer 145 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 M1606-M3 6120.03.000 Washer - Spring 4 M350 - 4977.08.001 Spool Valve Lever Housing 3

Flexi Himax

Hydraulic System

Steering Column Module (A353-3A)

7 E0901002P03 Limit Switch XCM-A1022

26F

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

Hydraulic System


Parts List


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 30096B 41285.01 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 35462 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 Load Sensing 100cc LT28 34979E 41242.08 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 - - - - -37 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 E3804004 5300.02.000 Horn 1 48 Volt41 30168 - Swivel Hose Bracket Assembly 1 Mounting Bracket42 30169B - Swivel Hose Bracket Assembly 1 Lower Swivel Bracket43 30170D - 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 E3804001 55327.01.000 Reverse Horn 153 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 3002937A 41338.05 Steering Cowl 1 Zapi MIDI only62 35032A 41378.01 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

Flexi Himax

Hydraulic System



1 E2301012 55508.07.000 Yellow LED Indicator 22 E2301011 55508.06.000 Red LED Indicator 23 E3601035 55481.01.003 Electronic Display 14 M1401-M8*35 6121.08.035 Screw - Cap Head 4 M8 x 355 M1317014 7598.04.000 Handle 26 E1622001 55498.02.000 Hill Start Switch 17 34957 42026.00 Sticker - Hill Start 18 3002937A 41338.05 Steering Cowl 19 3003371 42315.00 Dashboard Fascia 1

28

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

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

Parts List

Flexi Himax

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

Brake System

Pedal Plate Module (A354-1A)

A354

Brake System


1 34953 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 31631A 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 M1424-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 M1423-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

30F

Brake System

Rear Wheel Assembly (A354-2A)

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

Parts List


00 B352913 7738.11.000 Brake Back Plate Assembly 1 Lefthand; See A354-3A00 B352914 7738.10.000 Brake Back Plate Assembly 1 Righthand; See A354-3A01 0 7660.09.000 Hub Rear Assembly 1 -1 30315A 7738.08.000 Brake Cable 2 -2 33884 7738.08.002 Clip 23 M1321-M6 6566.06.000 Grease Nipple - Angled 2 M6 45°4 31997B 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 30237C 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 2 -12 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 6131.06.012 Screw - Countersunk Socket Hea 6 M6 x 12

15 M1211109 7635.09.000 Tyre - Rear 2 Plain Rubber 18" x 6"16 - 42359-00 Wheel Hub 2 Himax 1350 Chassis Only

- 42360-00 Brake Drum 2 Himax 1350 Chassis Only- 42361-00 Wheel Rim 2 Himax 1350 Chassis Only

Flexi Himax

17

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

Parts List

Brake System

Brake Backplate Assembly (A354-3A)


1 30612G - Brake Backplate R/H 11 30612G - Brake Backplate L/H 12 B350630B 7738.12.000 Adjuster 2 Manual3 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

32F

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

Parts List

Flexi Himax

A355

Control System

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

Control System

Electrical Module - Zapi Traction (A355-1B)

34F

Control System


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

Flexi Himax

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 55444.01.000 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

36F

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

Flexi Himax

Reverse Alarm Kit (A355-1B-01)

Control System


Parts List

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


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

38F

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

Flexi Himax

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

Parts List

Control System

Wiring Looms (A355-2A)

40F

fig. A355-2A: Truck Wiring Looms

Control System

Wiring Looms (A355-2A)

Parts List


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 Himax

42

A356

Flexi Himax

Mast System

Mast Support Assembly (A356-1A)

Mast System

Mast Support Assembly ………......…………………................. p44A356-3A-01 Fixed Stage Assembly ....................................................... p46A356-3A-02 Second Stage Assembly .................................................... p48 A356-3A-03 Third Stage Assembly ........................................................ p50

A356-5A Narrow Aisle Hydraulic Components Fixed Stage …................ p52A356-6A Narrow Aisle Hydraulic Components Third Stage ................... p54 A356-7A Tilting Carriage Assembly........................................................ p56

44F

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

Mast System

Mast Support Assembly (A356-1A)

Parts List

Ref NA Pt.No Description Qty Notes

1 41249.14 Mast Support Fabrication 1 02 41424.01 Slewing Ring 1 03 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 0

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 2 014 6588.01.000 Circlip 1 015 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 1 019 - Spindle 1 020 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 41896.01 Pivot Pin 1 Also see A352-1A-01

Flexi Himax

Fixed Stage Assembly

Mast System - High Capacity

Mast Fitting

46F

Fixed Stage Assembly

Mast Fitting - Fixed Stage Mast Assy - High Capacity Exploded View


Parts List


1 41640.xx Fixed Stage Mast Fabrication 1 Mast number required2 6596.03.000 Shim 6 45 ID x 0.53 7773.01.000 Roller Assembly 2 04 7694.01.000 Leaf Chain A/R Mast number required5 7694.02.000 Chain Anchor Bolt 2 BL 0534 MB16 7694.03.000 Chain Anchor Pin 2 8234-090 (PART OF REF 5)7 6131.16.000 Nyloc Nut 2 M168 6353.01.000 Cotter Pin 4 1/16" x 3/8" (Part of Ref 5)9 6351.01.000 Cotter Pin 2 1/8" x 1 1/2"

10 41404.xx Cylinder 2 Mast number required11 41410.00 Cylinder Clamp 2 012 6211.10.050 Bolt 4 M10 x 5013 6131.10.000 Nyloc Nut 4 M1014 55219.02.000 Limit Switch 1 015 55219.03.000 Limit Switch 1 016 40558.06 Limit Switch Bracket 1 017 7629.05.000 Rubber Buff 2 018 41583.00 Spacer 2 019 6161.10.010 Grub Screw 2 M10 x 1020 6566.06.000 Grease Nipple 2 M621 41343.01 Retainning Washer 2 Part of Mast Support Kit22 6121.10.030 Cap Head Screw 4 Part of Mast Support Kit23 6120.10.000 Spring Washer 4 Part of Mast Support Kit24 6610.01.000 Button Head Screw 2 M6 x 1225 6121.04.020 Cap Head Screw 2 M4 x 2026 6131.04.000 Nyloc Nut 2 M427 6120.06.000 Spring Washer 2 M628 6110.06.000 Plain Washer 2 M630 7771.01.000 Repair Washer A/R 3/8" I/Dia x 2" O/Dia

Flexi Himax

Second Stage Assembly


Mast Fitting

48F

Second Stage Mast Assembly


Mast Fitting - Second Stage Mast Assy - High Capacity Exploded View


Parts List

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 Retainers

9 40084-12 Instruction Label 2 Lifting Points10 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 Himax

Third Stage Assembly


Mast Fitting

50F


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

Mast Fitting - Third Stage Mast Assy-Heavy Duty Exploded View


Mast Fitting

Parts List

Ref NA Pt.No Description Qty

1 41642.xx Third Stage Mast Fabrication 1 Mast number required2 6596.03.000 Shim 6 45 ID x 0.53 7773.01.000 Roller Assembly 24 7694.02.000 Chain Anchor Bolt 4 BL 0534 MB15 7694.03.000 Chain Anchor Pin 4 8234-090 (PART OF REF 4)6 6131.16.000 Nyloc Nut 4 M167 6353.01.000 Cotter Pin 8 1/16" x 3/8" (Part of Ref 4)8 6351.01.000 Cotter Pin 4 1/8" x 1 1/2"9 7694.01.000 Chain 2 BL 0534

10 7629.05.000 Rubber Buff 211 41405.xx Cylinder 2 Mast number required12 41410-01 Cylinder Clamp 213 6131.08.000 Nyloc Nut 4 M814 41406-00 Pulley Yoke 215 41407-00 Chain Pulley 216 7671.01.000 Bearing 2 6306-2RS17 6428.01.000 Circlip 2 72 mm Internal18 40206-02 Spacer 419 41408-00 Hose Pulley 220 41409-01 Pulley Shaft 221 6150.30.000 Plain Washer 2 M30 Light22 6161.08.010 Grub Screw 2 M8 x 1023 6161.08.020 Grub Screw 4 M8 x 2024 6111.08.016 Set Screw 2 M8 x 1625 6120.08.000 Spring Washer 2 M826 6121.10.020 SKT Head Cap Screw 2 M10 x 2027 6120.10.000 Spring Washer 2 M10 x 2028 6131.10.000 Nyloc Nut 2 M10 x 20

Flexi Himax

Fixed Stage Mast (High Capacity) - Hydraulic Components


Mast Fitting

52F

Parts List

Hydraulic Components - Fixed Stage, Exploded View


Mast Fitting

Hydraulic Components - Fixed Stage


1 41655-200 Fee Lift Feed pipe 1 02 41441-XX Main Lift Feed pipe 1 Mast number required3 41442-XX Main Lift Feed pipe 1 Mast number required4 41656-200 Side Shift Feed pipe 1 05 41657-200 Side Shift Feed pipe 1 06 42128-00 Free Lift Feed pipe 1 07 41659-00 Side Shift Feed pipe 1 08 41660-00 Side Shift Feed pipe 1 09 42173-XX Main Lift Extension Pipe 1 BL 0534

10 42174-XX Side Shift Extension Pipe 2 011 41437-00 Manifold 1 Mast number required12 4971.05.000 Flow Control Cartridge 1 013 44057.17.000 Blanking Plug 1 M814 44057.12.000 Male Stud Coupling 1 015 44057.13.000 Bulkhead Coupling 1 016 44057.14.000 Male Stud Coupling 4 6306-2RS17 44057.15.000 Bulkhead Coupling (Body Only) 4 72 mm Internal18 44057.18.000 Straight Coupling 8mm 4 019 44057.16.000 Straight Coupling 15mm 2 020 41452.XX Free Lift Hose Assembly 1 021 41453.XX Sideshift Hose Assembly 2 M30 Light22 41451-00 Bulkhead Bracket 1 M8 x 1023 4627.05.000 Pipe Clamp 3 M8 x 2024 4627.04.000 Pipe Clamp 3 M8 x 1625 6111.08.020 Set Screw 2 M826 6611.01.000 Button Head Screw 6 M10 x 2027 6610.01.000 Button Head Screw 2 M10 x 2028 6110.08.000 Plain Washer 2 M1029 6120.08.000 Spring Washer 2 030 6120.06.000 Spring Washer 3 031 4975.09.000 Bracketed Tee 1 032 4975.08.000 Equal Elbow 2 033 4975.07.000 Nipped Adapter 2 034 4975.03.000 Tube Nut 4 035 4975.04.000 Olive 4 036 4976.01.000 Nylon Tube A/R 037 4690.01.000 P' Clip 11 038 6600.01.000 Taptite Screw 11 039 6111.06.030 Set Screw 1 040 0 Rupture Valve Set to 1.6 mm 2 Part of M/L Cylinder

0 0 0 0100 44063.01.000 Walform Seal 0 8 mm101 44063.02.000 Walform Seal 0 10 mm102 44063.04.000 Walform Seal 0 15 mm103 44063.05.000 Walform Spacer Ring 0 10 mm

Flexi Himax



Mast Fitting

54F


Hydraulic Components - Third Stage, Exploded View


Hydraulic Components - Third Stage

Parts List

1 41648-200 Sideshift Feed Pipe 1 02 41649-200 Sideshift Feed Pipe 1 03 42175-XX Sideshift Extension Pipe 2 Mast number required4 41454-XX Sideshift Hose - Secondary 2 Mast number required5 0 Sideshift Hose - Primary 2 See LG0017-426 44057.15.000 Bulkhead Coupling (Body Only) 4 8L7 44057.11.000 Male Stud Coupling (Body Only) 2 M14 - 8L8 44057.14.000 Straight Coupling (Body Only) 2 8L9 4627.07.000 Pipe Clamp 2 8 mm Single

10 42175-XX Free Lift Hose Assembly 1 See LG0017-4211 41650-00 Link Pipe 1 12 Dia12 41457-02 Extension Pipe 1 12 Dia13 41651-00 Feed Pipe 1 15 Dia14 44057.05.000 Bulkhead Elbow 1 15L15 44057.08.000 Adjustable Elbow 1 12L16 44057.09.000 Reducing Coupling 1 15L - 12L17 44057.10.000 Adjustable Elbow 2 12L18 44057.07.000 Male Stud Coupling (Body Only) 2 3/8" BSP - 12L19 0 Rupture Valve - Set to 1.6 2 Part of F/L Cylinder20 6611.01.000 Button Head Screw 2 M6 x 3021 0 022 0 023 0 024 0 025 0 026 0 027 0 028 0 029 0 030 0 0

100 44063.01.000 Walform Seal 0 8 mm101 44063.02.000 Walform Seal 0 10 mm102 44063.04.000 Walform Seal 0 15 mm103 44063.05.000 Walform Spacer Ring 0 10 mm

Flexi Himax

Mast System

Tilting Carriage Assembly (A356-4A)


00 - Fork Carriage Hydraulic Assy 1 See A356-7A1 - Lifting Carriage 1 02 - Intermediate Frame 1 03 4997.44.020 Fork Carriage 1 04 4997.44.005 5 0

4a 4997.44.006 2 05 4997.44.004 Piston Rod 2 06 4997.44.024 Stripper 2 07 4997.44.022 Washer 2 08 4997.44.025 Groove Ring 2 09 4997.44.023 Sleeve Bearing 2 010 - Thread Pin 2 M8 x 1611 4997.44.026 Bolt 2 012 4997.44.032 Grease Nipple 4 M8, tapered13 4997.44.023 Bearing Bush 2 014 6121.16.030 Screw - Cap head 1 M16 x 3015 6120.16.000 Washer - Spring 1 M1616 4997.44.019 Guide Roller 2 017 4997.44.035 Nut - Plain 4 M3018 4997.44.033 Grease Nipple 2 M819 6121.12.060 Screw - Cap head 2 M16 x 6020 4997.79.001 Holder 2 021 6121.12.030 Screw - Cap head 2 M12 x 3022 6120.12.000 Washer 2 M1223 4997.44.021 Cover Sheet 1 024 6121.06.016 Screw - Cap head 5 M6 x 1625 41936.xx Fork 2 (Not Shown)

56

Sliding Piece

Parts List

Mast System

Hydraulic Components - Tilting Carriage

Tilting Carriage Assembly, Exploded View


1 4997.44.001 Solendoid Valve 1 02 4997.44.002 Valve 1 03 4997.44.003 Cylinder - Tilt 2 04 4997.44.010 Tube 1 05 4997.44.009 Pipe 1 06 4997.44.016 Tube 1 07 4997.44.014 Tube 2 08 4997.44.013 Tube 1 09 4997.44.011 Tube 1 0

10 4997.44.012 Tube 1 011 4997.44.007 Pipe 1 012 4997.44.008 Tube 1 013 4997.44.015 Hose Line 2 014 44057.22.000 Coupling - Elbow 6 8L15 4997.44.028 Coupling 4 016 - Connector 8 017 4997.44.029 Coupling 2 018 4997.44.030 Coupling - T 2 019 44057.04.000 Bulkhead Coupling 2 8L20 4997.44.031 Connector 2 021 6111.08.016 Screw - Hex Head 2 M8 x 1622 6121.06.040 Screw - Cap Head 2 M6 x 4023 - Tube Clip 2 024 6121.06.030 Screw - Cap Head 2 M6 x 30

fig. A356-7A: Narrow Aisle Hydraulic Components - Tilting Carriage, Exploded View

Parts List

58F

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

Accessory System

Labels (A357-1A)

A357

Accessory System

Flexi Himax

Labels (A357-1A)

fig. A357-1A-1: Labels

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

Accessory System


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 Retainers

9 40084-12 Instruction Label 2 Lifting Points10 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

60F


Seal Kit (A357-2A)

Parts List

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

Parts List

Accessory System

41404.20 GKN41404.30 Tail Lift41404.40 Rangers41405.20 GKN41405.30 Tail Lift41405.40 Rangers

3 (0050011320) 4997.44.017 Seal Kit - Sideshift Cylinder 2 Seal Kit A4 (0050071220) 4997.44.018 Seal Kit - Tilt Cylinder 25 - 4977.03.000 Seal Kit - Spool Valve Assebly 1 Seal Kit

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

Parts List


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 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 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

A358

Seal Kit - Main Lift Cylinder

Seal Kit - Free Lift Cylinder

1 B350738 2

2 B350739 2

62

A358

Index

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

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

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