Flexi G4 AC Parts Manual

Flexi G4
Parts Manual
42055-00 Is
Contents
A350 - Revisions 2
A350-1A - Document Revision Details 2
A351 - Transmission System 3

A351-1A - Front Axle Assembly 4
A351-2A - Axle and Transmission Assembly 6
A352 - Chassis Fitting System 9

A352-1A - Chassis Kit 10
A352-1A-00 - Steering Motor Extension 12
A352-1A-01 - Additional Chassis Parts 13
A532-2A - Seat and Covers 14
A352-3A - Overhead Guard 16
A352-4A - Battery Tray Assembly 17
A352-5A - Controls Assembly 18
A353 - Hydraulic System 19

A353-1A - Oil Tank Module 20
A353-1A-00 - Lift Motor Module 22
A353-1A-01 - Steer Motor Module 23
A353-2A - Spool Valve Assembly 24
A353-3A - Steering Column Module 26
A353-3A-00 - Steering Cover and Dash 28
A354 - Brake System 29

A354-1A - Pedal Plate Module 30
A354-2A - Rear Wheel Assembly 31
A354-3A - Brake Backplate Assembly 32
A355 - Control System 33

A355-1B - Electrical Module - Zapi Traction 34
A355-1B-00 - Solenoid Switches 37
A355-1B-01 - Reverse Alarm Kit 38
A355-1B-02 - Cold Store Additions (Electrical) 39
A355-1B-02b - Cold Store Additions (Solenoid SW80A 24V) 39
A355-2A - Wiring Looms 40
A356 - Mast System 43

A356-1A - Mast Support Assembly 44
A356-2A - Mast Assembly 46
A356-3A - Mast Fitting 47
A356-3A-01 - Fixed Stage Assembly 48
A356-3A-02 - Second Stage Assembly 50
A356-3A-03 - Third Stage Assembly 52
A356-4A - Narrow Aisle Fork Carriage Assembly 54
A356-4A-00 - Alternative Fork Carriage Assembly 55
A356-5A - Narrow Aisle Hydraulic Components - Fixed Stage 56
A356-6A - Narrow Aisle Hydraulic Components - Third Stage 59
A357 - Accessory System 61

A357-1A - Labels 62
A357-2A - Seal Kit 64
A357-3A - Cold Store Additions (Mechanical) 64
A358 - Index 65
A358-1A - By Part Name i
A358-2A - By Part Reference Number - NA xiii
A358-3A - By Part Reference Number - TW xxiii
Flexi G4
Revisions
Document Revision Details (A350-1A)
Rev Date Revised By Description Appro
A 14 / 03 / 2013 H Clemmet First Issue P Ca

B 05 / 06 / 2013 H Clemmet Alternate Carriage reference numbers amended P Ca
C 12 / 07 / 2013 R Bennett Updated , mast details P Ca
D
2
A351
Transmission
System
A351-1A - Front Axle Assembly ………………………………………. p4

A351-2A - Axle and Transmission Assembly .……………….………. p6
Flexi G4
Transmission System
Transmission System
Front Axle Assembly (A351-1A)
fig. A351-1A: Front Axle Assembly, Exploded View
Transmission System
Front Axle Assembly (A351-1A)
Parts List
Ref TW Pt No NA Pt.No Description Qty Notes
00 B350686 7661.09.000 Front Wheel Assembly 2 Contains reference parts 1 & 2

01 B350603 4978.15.000 Transmission Assembly 1 See A351-2A, page 6
1 M1211080 7635.14.000 Tyre - Front 2 16.25 x 7 x 11.25 Plain Black
2 30106C 41218.00 Hub 2
3 30114C 41288.02 Axle Support Fabrication 1
4 30107A - Pin 1 To join items 3 & 7
5 30108 - Washer 1 M8
6 30102B 41288.04.02 Crossbeam 1
7 30104C 41045.04 Front Counterweight 1
8 M0919-GE50ES 7644.01.000 Bearing 2
9 M1312-R75 6422.01.000 Circlip 2
10 M1401-M20*60 6121.20.060 Screw - Socket Cap Head 1 M20 x 60
11 M1602011 - Washer 1 M10
12 M1401-M20*70 6211.20.070 Bolt - Hex Head 1 M20 x 70
13 M1606-M20 6120.20.000 Washer - Spring 5 M20
14 M1321001 6566.04.000 Grease Nipple 2 M10
17 M1423009 6121.20.060 Screw - Cap Head 2 M20 x 60
18 3002772 42380.00 Terminal Mounting Plate 1
19 E0303031 55530.01.000 Terminal Block 1
20 M1602-M6 6110.06.000 Washer - Flat 2 M6
22 M1402-M6*16 6121.06.016 Screw - Cap Head 2 M6 x 16
23 M1602005 6110.08.000 Washer - Flat 2 M8
26 3004375 42330.00 Cable Protection plate 1
29 55492-08-000 Traction Motor 1 AC Schabmueller
30 30114P03 - Axle Clamp 2
34 - 4978.15.005 Wheel Nut 12
Flexi G4
Transmission System
Axle and Transmission Assembly (A351-2A)
fig. A351-2A: Axle and Transmission Assembly, Exploded View
Transmission System
Axle and Transmission Assembly (A351-2A)
Parts List
00 B350603 4978.15.000 Transmission Assembly 1 Parts: All excluding 51

01
B350605 - Differential Assembly 1 Parts: 10, 26, 27, 30, 31, 39, 40, 41, 54, 55 and 02
02 B350568 - Differential Case 1 Parts: 28, 29
1 30095B 300095 Front Tyre Base Axle 1
2 30092E 30092 Gear Casing 1
3 30088A 30088 + 30094 Spacer 2
4 M1328-10*32 M1308.10*32 Key 1 10 x 8 x 32
5 30091A 30091 Cover Plate 2
6 M1424-M8*20 - Bolt 6 M8 x 20
7 M0909-30307 4978.15.002 Taper Roller Bearing 3 30307
8 30074 30074 Intermediate Gear 1
9 30073A 30073 Wheel-Helical 1
11 30093F 30093 Gear Casing 2 1
12 M1301-16*20 M1301.16*20 Pin 2 16 x 20
13 30090B 30090 Connecting Shaft 1
14 M1301-16*40 M1301.16*40 Pin 4 16 x 40
15 30089A 30089 Front Tyre Base Axle 1
16 M0702053 4978.15.001 O-ring 2 TB80 x 105 x 13 (ACM)
17 30085A 30085 Front Hub 2
18 30086 30086 Axle Screw 12
19 M0801-AS234 - O-Ring 2
21 M1422002 M1422.CBS5.8 Screw - Cap Head 6 CBS5-8
22 M1301-10*30 M1301.10*30 Pin 4 10 x 30
23 30083A 30083 Nut - Lock 2
24 30084A 30084 Nut - Lock 2
25 30079B 30079 Front Axle-Long 1
26 M1424004 M1401.M10*30 Bolt - Hex Head 12
27 32098 31502017 Differential Gear 2
28 30082B 30082 Differential Case 1 M10 x P1-25 x 30
29 30081B 30081 Differential Case 1
30 32096 32502009 Washer - Flat 2
31 M1424-M8*65 M1402.M8*65 Bolt - Hex Head 12 M8 x 65
32 30078B 30078 Front Axle-Short 1
34 30076A 4978.15.010 Input Pinion-Helical 1
35 30071 30071 Spacer 1
36 - - - - -
37 30075 30075 Helical Gear 1
38 31594 92502010 Breather 2
39 32104 32502015 Differential Gear 4
40 32102 32502014 Differential Washer 4
41 32100 30080 Differential Spider 1
42 M1424007 - Bolt 6
43 M0604008 92502010 Screw Plug 1 Breather
44 30296 4978.15.018 Washer 1
45 30297 - Washer 1
M1423008 6111.10.030 Bolt - Hex Head 7 M10 x 30
46
M1402-M10*25 6211.10.025 Bolt - Hex Head 1 M10 x 25
47 M0702052 4978.12.014 O-ring 1 Output shaft seal ø42 x ø72 x 8mm
48 M0604005 - Bung 2
49 M1424009 - Bolt 5
50 30087 4978.15.005 Nut - Wheel 12
51 55492-08-000 Traction Motor 1 AC Schabmueller
52 30094 4978.15.017 Shim 2
53 M1602-M10 6110.10.000 Washer - Flat 8 M10
Flexi G4
A352
Chassis Fitting
System
A352-1A - Chassis Kit ..................................................................... p10

A352-1A-00 - Steering Motor Extension ............................... p12
A352-1A-01 - Additional Chassis Parts ................................. p13
A352-2A - Seat and Covers ............................................................ p14
A352-3A - Overhead Guard ............................................................ p16
A352-4A - Battery Tray Assembly ................................................... p17
A352-5A - Controls Assembly ......................................................... p18
Flexi G4
Chassis Fitting System
Chassis Kit (A352-1A)
fig A352-1A: Chassis Kit, Exploded View
10
Parts List
00 - - Steering Motor Extension 1 See List A352-1A-1

01 - - Additional Chassis Parts 1 See List A352-1A-2
02 - 41386.02 Swivel Hose Bracket 1 See List A353-3A
1 34951H 41265.17 Chassis Fabrication 1 Pallet Trick Batt. Removal
1a - 41277.05 Stub Axle 2
1b - - Leg Guards 2
1c 34946 - Step Plate 1
42181.01 1 Left-hand
1d - Lower Step Plate
42181.02 1 Right-hand
2 M1602028 6110.12.000 Washer - Flat 4 M12
5 30262B 41328.02 Quarter Ballast 1 Left Hand Side
6 34898 6453.01.000 Roll Pin 2
7 30263C 41328.01 Quarter Ballast 1 Right Hand Side
10 30372 7093.01.000 Brass Tee Piece 1
13 30373A 6581.03.000 Brake Pipe 1 R/H Wheel to Tee
14 30374A 6581.04.000 Brake Pipe 1 L/H Wheel to Tee
15 30375A 6581.05.000 Brake Pipe 1 Tee to Brake Master Cylinder
16 3005090 6517.02.000 Hole Insert 6 Side Ballast ø42mm
17 30250B 41345 Battery Plug Bracket 1
20 30260C 41320.02 Side Ballast 1 Left Hand Side
21 E3805003 55131.14.000 Fan 2 48 Volt
22 M1602-M4 6110.04.000 Washer - Flat 8 M4
24 30261C 41320.01 Side Ballast 1 Right Hand Side
26 3001163 - Anti-Slip Plate Left 1
27 3001167 - Anti-Slip Plate Right 1
28 30290 41318 Electrical Mounting Bracket 1
29 M1423-M10*30 6111.10.030 Bolt 2 M10 x 30
31 - 41286 Steer Motor Mounting Plate 1
32 - 4690.01.000 Pipe Clip (not shown) 2 1/4"
Flexi G4

Steering Motor Extension (A352-1A-00)
fig. A352-1A-00 - Steering Motor Extension, Exploded View
Parts List

2 M1501-M12 6111.12.000 Nut - Plain 8 M12
3 30077F 41535.00 Steer Pinion Shaft 1
4 M0901-6210ZZ 7735.01.000 Bearing 2 6210-2RSI ø90 x ø20 x 50mm
5 30419B 41536.01 Bearing Housing 1 To suit Danfoss
6 M1312-S50 6588.01.000 Circlip 1 M50
7 M0305006 4980.01.000 Hydraulic Steer Motor 1 Danfoss OMSW400
9 35943 4975.06.000 Brass Straight Fitting 1 1/4" BSP - 8mm T
10 35455 4443.01.000 Connector - Male 2 1/2" - 3/8" BSP (to Steer Lock Valve)
11 M0801015 4520.01.000 Seal 2 1/2" BSP Dowty
12 35894 - Tee Connector 1
13 M0511001 4976.01.000 Nylon Pipe 2 Steer Motor Extension Bleed (/metre)
12

Additional Chassis Parts (A352-1A-01)
fig. A352-1A-01: Additional Chassis Parts, exploded view
Parts List
Ref NA Pt.No Description Qty Notes
1 41265.17 Chassis Fabrication 1 Pallet Trick Batt. Removal

2 41577.00 Battery Retaining Assembly 1
2a 41577.01 Battery Tank Fixed Support 1 Part of item 2
2b 41577.02 Buckle Board 1 Part of item 2
2c 41577.03 Pin 1 Part of item 2
3 - Split Pin 2 Battery Retainer
4 6120.10.000 Washer - Spring 2 M10
5 6121.10.025 Setscrew - Cap Head 2 M10 x 25
6 6120.08.000 Washer - Spring 4 M8
7 6111.08.025 Setscrew - Hex Head 2 M8 x 25
8 6110.08.000 Washer - Flat 4 M8
9 - Bolt - Button Head 4 M4 x 25
10 6110.04.000 Washer - Flat 4 M4
11 6120.04.000 Washer - Spring 5 M4
42032.02 1 Right-Handed
12 Battery Lid Bracket
42032.03 1 Left Handed
13 7763.01.000 Extension Spring 2 12 O/D x 1-5 Wire x 35 F/L
14 41316.00 Nut - Dome Face 2 M10
15 6211.12.060 Bolt - Hex Head 2 M12 x 60
16 6110.12.000 Washer - Flat 8 M12
17a Handbrake Cable Linkage 1 Set Reference 41302-12
17b 41302.30 Handbrake Cable Linkage 1
17c Handbrake Cable Linkage 1
18 7626.10.000 Bush - Glacier 2 PM1215 DX
19 6111.12.000 Nut - Plain 2 M12
20 6120.12.000 Washer - Spring 6 M12
21 6111.04.000 Nut - Plain 4 M4
Flexi G4
Seat and Covers (A352-2A)
fig. A352-2A: Seat & Covers, Exploded View
14
Seat and Covers (A352-2A)
Parts List
1 41339.01 Battery Lid 1

2 41337.10 Front Electronics Cover 1
3 41390.00 Arm Rest Cushion 1
4 41385.00 Seat Pan 1
5 41336.03 Front Nose Cone Cover 1
6 7659.01.000 Gas Strut 1 650N
7 42046.00 Seat Wire Plate 1 Protects Seat Switch Cable
8 55497.01.000 Document Holder 1
9 7633.27.000 Seat 1 MSG 20 inc- Belt (PVC)
10 41321.06 Floor Plate 1
11 6131.06.012 Bolt - Countersunk 4 M6 x 12
12 6221.08.030 Bolt - Cap Head 5 M8 x 30
13 6131.08.000 Nut - Nyloc 5 M8
14 7598.05.000 Latch 2 For Battery Lid
15 6110.10.000 Washer - Flat 4 M10
16 41372.00 Seat Frame 1
17 6121.10.040 Screw - Cap Head 4 M10 x 40
18 6610.01.000 Screw - Button Head 4 M5 x 12
19 4976.01.000 Nylon Pipe 1 8mm diameter ( /metre)
20 41394.00 Seat Stop 1
21 6600.01.000 Screw - Pozi Pan 2 M10 x 25 Taptite
22 6110.10.000 Washer - Flat 4 M10
23 7307.01.000 Edging Strip 1 ( /metre)
24 41342.00 Direction Lever Cover 1
25 6110.08.000 Washer - Flat 7 M8
26 - - - -
27 - - - -
28 6131.06.000 Nut - Nyloc 2 M6
29 6120.08.000 Washer - Spring 4 M8
30 41372.02 Rubber Buffer 3
31 7703.03.000 Rubber Buffer 3
32 6110.06.000 Washer - Flat 2 M6
33 6121.06.020 Screw - Cap Head 2
34 7633.27.005 Seat Runners 2
35 - Pipe Connector 1
36 - Seat Frame Support 1 Contains 1 x #30 & 1 x #31
37 - Seat Frame Buffer 1 Contains 1 x #30 & 1 x #31
38 41944.00 Hose Protection Funnel 1
39 - - - -
40 42350.00 Seat Latch 1 Includes 40a, Striker Plate
41 - - - -
42 - - - -
43 - - - -
44 6121.05.010 Bolt - Dome Head 2 M5 x 10
45 41394.00 Seat Stop Plate 1
46 - - - -
47 - - - -
48 6211.04.050 Bolt - Hex Head 4 M4 x 50
49 55131.14.000 Fan 2 48 Volt
50 6112.04.000 Nut - Plain 4 M4
Flexi G4
Overhead Guard (A352-3A)
fig. A352-3A: Overhead Guard, Exploded View
Parts List
1 41268.10 Overhead Guard 1

2 6171.14.045 Bolt - Durlock 8 M14 x 45
3 6120.14.000 Washer - Spring 8 M14
4 5306.06.000 Headlight 2 24V, 48V
5 0 0 2 M8 x 30
6 6111.08.000 Nut - Plain 2 M8
7 42272.00 Headlight Guard 2
8 6210.08.016 Bolt - Dome Head 4 M8
9
5676.14.000 Beacon 1 Also see 5676-10-000 (Beacon) and 5676-11-000 (Guard)
10 6211.06.020 Bolt - Hex Head 3 M6 x 20
11 6131.06.000 Nut - Nyloc 3 M6
12 7404.03.000 Rear View Mirror 1
13 6121.05.010 Screw - Cap Head 2 M5 x 10
14 6110.05.000 Washer - Flat 1 M5
16
Battery Tray Assembly (A352-4A)
fig. A352-4A: Battery Tray Assembly
Parts List
1 34948 41369.30 Battery Tank 1

2 30418 - Support Leg 1 Part of 41369-10
3 35664 40366.03 Battery Connection Bracket 1
4 M1410-M6*12 6610.01.000 Bolt - Button Head 2 M6 x 12
5 M1503-M6 6111.06.000 Nut - Plain 2 M6
6 E3801008 - Cell 24 5HPzS-775
7 - 55385.13.000 Battery Connection 1
8 M1401-M6*50 6221.06.050 Setscrew - Cap Head 4 M6 x 50
9 M1602-M6 6110.06.000 Washer - Flat 8 M6
10 M1501-M6 6131.06.000 Nut - Nyloc 4 M6
Flexi G4
Controls Assembly (A352-5A)
fig. A352-5A: Controls Assembly
Parts List
- Ignition Switch
1 1
55523.01.005 Key Barrel
2 5202.04.000 Direction Lever 1
3 7633.19.001 Seat Switch 1
4 41340.00 Spool Valve Lever Cover 1
5 6549.01.000 Jack Nut 4 M4
6 55519.02.000 Headlight Switch 1 55520-02-000 for switch base
7 6111.06.020 Bolt - Hex Head 4 M6 x 20
8 - Lift Lever Assembly 1 See List A353-2A
9 - Tilt Lever Assembly 1 See List A353-2A
10 - Sideshift Lever Assembly 1 See List A353-2A
11 7620.02.000 Handbrake Assembly 1 See List A353-2A
12 55498.01.000 Horn Switch 1
18
A353
Hydraulic
System
A353-1A - Oil Tank Module……………………………………..……. p20

A353-1A-00 - Lift Motor Module ……………………………... p22
A353-1A-01 - Steer Motor Module ....................................... p23
A353-2A - Spool Valve Assembly……………………………………. p24
A353-3A - Steering Column………………………………………….. p26
A353-3A-00 - Steering Cover & Dash ...…………………..... p28
Flexi G4
Hydraulic System
Oil Tank Module (A353-1A)
fig. A353-1A: Oil Tank Module, Exploded View
20
Hydraulic System
Parts List
1 30207C 41282.03 Oil Tank 1 Top profile - 41282-05

2 30211E 41282.01 Oil Tank Lid 1 Lift Motor
3 30212D 41282.04 Oil Tank Lid 1 Steer Motor
4 30206 41282.02 Gasket 2
5 E2102002 5454.02.000 Lift Pump Motor 1 See A353-1A-01
6 3000816 4981.03.000 Steering Pump 1 PLP20-8D
7 E2102003 55309.02.000 Steering Pump Motor 1 See A353-1A-02
8 3000815 44047.03.000 Lift Pump 1 PLP20-14S
9 30623 4004.01.000 Serrated Drive 2
10 M0303002 4634.01.000 Suction Filter - Steering 1
11 M0303003 4632.01.000 Suction Filter - Lift 1 1" BSP
12 M0303004 4959.01.000 Return Filter Assembly 1
13 30614 4994.03.000 Cast Flanged Elbow 3 1/2" BSP
14 30615 4994.01.000 Cast Flanged Elbow 1 3/4" BSP
15 35458 4489.01.000 Connector 1 1" BSP - 1/2" BSP M/M
16 34177 4409.01.000 Connector - Male 2 3/4" BSP - -3/4" BSP M/M
17 M0601010 4466.01.000 Connector - Male 1 1" BSP - 3/4" BSP M/M
18 M0601021 4441.01.000 Connector - Male 2 1/2" BSP - 1/2" BSP M/M
19 33828 4452.01.000 Connector - Male 2 3/4" BSP - 1/2" BSP M/M
20 35467 4487.02.000 Connector - Three-Way Fitting 1 1/2" M - 1/2" F - 3/8" M+G2209 BSP
21 35471 - Connector 1
22 M0507002 4976.01.000 Nylon Pipe 1 8mm diameter (/metre)
23 M1613006 4524.01.000 O-ring 1 1" BSP Dowty
24 3001119 - Connector 1
25 30344A 3729.46 Hose 1 Steer Pump Suction
26 30345 3729.47 Hose 1 Lift Pump Suction
27 31790A 3729.44 Steel Tube 1 Steer Pump Pressure
28 31791B 3729.45 Steel Tube 1 Lift Pump Pressure
29 M0505001 3729.43 Oil Pipe 1 Steer Motor Bleed
31 M1424-M8*25 6121.08.025 Screw - Socket Head 4 M8 x 25
32 M1613005 4520.01.000 O-ring 1 1/2" BSP Dowty
33 M1423-M6*20 6111.06.020 Setscrew 12 M6 x 20
36 M0303005 4959.02.000 Return Filter 1
37 - 4959.03.000 Breather Filter 1
38 M0303006 4959.12.000 Gasket 1
39 35988 - Connector 1
40 34115 5454.02.007 Carbon Brush 8
41 34505 55309.02.003 Carbon Brush 4
42 M1613004 4523.01.000 O-ring 3 3/4" BSP Dowty
43 - 5882.01.000 Rubber Terminal Boot 4
44 - - Nut 2 As part of items 6 and 8
45 M0203014 4975.01.000 Male Stud Elbow Fitting 2 1/4" BSP - 8mm elbow
Flexi G4
Hydraulic System

Lift Motor Module (A352-1A-00)
fig. A353-1A-00: Lift Motor Module, Exploded View
Parts List
1 - 55294.04.001 Drive Endhead 1 H95-003A

2 - 55294.04.002 Bearing 1 BR-107
3 - 55294.04.003 Drive End Bearing Circlip 1 H-014
4 - 55294.04.004 Fan 1 A90-109C
5 - 5454.02.003 Armature & Fan Assembly 1 BM5-3006
6
- 5454.02.004 Field Coil Kit 1 BM5-3005S
7
8 - 5454.04.000 Brush Spring 8 B89-016
9 - 5454.02.007 Brush 8 A89-012A
10 - 55295.03.007 Brush Plate Assembly 1 J89-1064
11 - 5454.02.005 Brush Lead Assembly Kit 1 L91-2035S
12 - 55294.04.008 Bearing 1 BR-205
13 - 55294.04.009 Washer - Wavy 1 H-016
14 - 5454.02.001 Commutator Endhead 1 L97-002C
15 - 5454.02.006 Headband Assembly 1 HB-1052
16 - 5454.02.000 Lift Motor Complete 1
16a - 5454.02.000S Lift Motor Complete 1 Service Exchange
22
Hydraulic System

Steer Motor Module (A353-1A-01)
fig. A353-1A-01: Steer Motor Module, Exploded View
Parts List
1 - 55294.01.001 Drive Endhead 1 H95-003A

2 - 55294.04.002 Bearing 1 BR-107
3 - 55294.04.003 Drive End Bearing Circlip 1 H-014
4 - 55294.04.004 Fan 1 A90-109C
5 - 55309.02.001 Armature & Fan Assembly 1 BM5-3146
6 - 55309.02.002 Field Coil Kit 1 BM5-3005AS
7 - 55309.02.003 Brush 4 A97-1012
8 - 5454.04.000 Brush Spring 4 B89-016
9 - 55309.02.004 Brush Plate Assembly 1 A88-1064
10 - 55294.04.007 Brush Lead Assembly Kit 1 L93-2035AS
11 - 55294.04.008 Bearing 1 BR-205
12 - 55294.04.009 Washer - Wavy 1 H-016
13 - 55309.02.005 Commutator Endhead 1 G97-102A
14 - 55309.02.006 Headband Assembly 1 HB-1061
15 - 55309.02.000 Steer Motor Complete 1
15b - 55309.02.000S Steer Motor Complete 1 Service Exchange
Flexi G4
Hydraulic System
Spool Valve Assembly (A353-2A)
fig. A353-2A: Spool Valve Assembly, Exploded View
24
Hydraulic System
Spool Valve Assembly (A353-2A)
Parts List
1 4977.08.000 Spool Valve 1

2 41317 Spool Valve Mounting Bracket 1
3 7620.02.000 Handbrake Assembly 1
4 4970.03.000 Flow Regulator 2
5 4667.01.000 Hold Valve 1 48V
6 5277.01.000 Spool Valve Micro Switch 1
55219.02.000 1
7 Limit Switch XCM-A1022
55219.03.000 1
8 7668.01.000 Handbrake Cable 1
9 41348.08 Lever 1 1 Side-shift
10 41348.07 Lever 2 1 Tilt
11 41348.06 Lever 3 1 Lift
12 7638.07.000 Lever Knobs 1 Side-shift
13 7638.06.000 Lever Knobs 1 Tilt
14 7638.05.000 Lever Knobs 1 Lift
15 41391-00 Retaining Strap 1
16 41393 Bolt - Hex Head 1 Handbrake
17 6121.10.035 Screw - Cap Head 1 M10 x 35 (cut down)
18 6221.10.020 Screw - Cap Head 1 M10 x 20
19 4813.01.000 Connector 2 1/4" - 3/8" BSP M/M
20 6601.01.000 Screw - Cap Head 4 M4 x 25 Taptite
21 4437.01.000 Blanking Plug 1 1/2" BSP
22 4520.01.000 O-ring 4 1/2" Dowty
23 4441.02.000 Coupler M0601021 4 1/2" - 1/2" BSP M/M
24 - Spacer 2
25 (3729.82) Rubber Hose 1
26 (3729.87) Rubber Hose 1
27 (3729.86) Rubber Hose 1
28 (3729.84) Rubber Hose 1
29 (3729.83) Rubber Hose 1
30 (3729.34) Rubber Hose 1 S/S Restrictor - Mast
31 (3729.12) Rubber Hose 1 S/S Spool - Mast
32 (3729.85) Rubber Hose 1
33 (3729.6) Rubber Hose 1
34 (3729.61) Rubber Hose 1
35 6221.08.055 Screw - Cap Head 3 M8 x 55
36 6120.08.000 Washer - Spring 3 M8
37 6111.06.040 Screw - Cap Head 2 M6 x 40
38 - Solenoid 1
39 - Connector 1 To Item #34
40 4521.01.000 O-ring 4 1/4" BSP Dowty
41 4522.01.000 O-ring 4 3/8" BSP Dowty
42 - Connector 1 To Item #33
43 4914.02.000 Adjustable Elbow 1 1/2" BSP
44 - Spacer 1
45 - Washer - Flat 1 Dowty
46 6110.10.000 Washer - Flat 2 M10
47 6120.10.000 Washer - Spring 2 M10
48 6111.10.030 Bolt - Hex Head 2 M10 x 30
49 6120.03.000 Washer - Spring 2 M3
50 4977.08.001 Spool Valve Lever Housing 3
Flexi G4
Hydraulic System
Steering Column Module (A353-3A)
fig. A353-3A: Steering Column Module, Exploded View
26
Hydraulic System
Parts List
00 - Steering Assembly 1 Contains Items; 6 - 10

01 - Steering Cover & Dash 1 Contains Items; 18, 36, 51, 58-61 & 63-65
1 - - - -
2 - - - -
3 - - - -
4 - - - -
5 - - - -
6 - Nut 1
7 7647.11.000 Steering Wheel 1 ø 13"
8 7646.06.000 Steering Column 1
9 - Steering Wheel Cover 1 As part of Item # 7
10 - Label 1 See A357-1A
11 6120.10.000 Washer - Spring 10 M10
12 41285.01 Steering Column Support 1
13 6110.12.000 Washer - Flat 1 M12
14 41365.00 Hinge Screw 2 M12 x 25
15 6110.12.000 Washer - Flat 2 M12
16 6111.10.030 Bolt - Hex Head 2 M10 x 30
17 7601.01.000 Adjustable Hand Lever 1 Locking Lever
18 55481.01.003 Zapi Display Unit 1 Panel Kit
19 4443.01.000 Connector 4 1/2" BSP - 3/8" BSP M/M
20 4520.01.000 O-ring 4 1/2" BSP Dowty
21 (3729.101) Rubber Hose 1 Orbital / Lock Valve
22 (3729.100) Rubber Hose 1 Orbital / Lock Valve
23 (3729.107) Rubber Hose 1 Priority Valve / Orbital
24 (3729.105) Rubber Hose 1 Orbital / Tank Filter
25 (3729.102) Rubber Hose 1 Lock Valve / Steer Motor
26 (3729.103) Rubber Hose 1 Lock Valve / Steer Motor
27 44001.09.000 Steel Orbital Valve 1 Load Sensing 100cc LT
28 41242.08 Steering Column Mount 1
31 4522.01.000 O-ring 5 3/8" BSP Dowty
32 4973.01.000 Steering Lock Valve 1
33 6110.08.000 Washer - Flat 2 M8
34 6121.08.090 Screw - Cap Head 2 M8 x 90
35 (3729.108) Rubber Hose 1 Lock Valve / Tank
36 - - - -
37 5400.01.000 Resistor 2 Paired with Item #50
38 4521.01.000 O-ring 3 1/4" BSP Dowty
39 - Steel Tube 2
40 5300.02.000 Horn 1 48 Volt
41 - Swivel Hose Bracket Assembly 1 Mounting Bracket
42 - Swivel Hose Bracket Assembly 1 Lower Swivel Bracket
43 - Swivel Hose Bracket Assembly 1 Upper Swivel Bracket
44 6121.10.100 Screw - Cap Head 2 M10 x 100
45 6131.10.000 Nut - Nyloc 2 M10
46 6131.12.000 Nut - Nyloc 1 M12
47 C65983.01 Pressure Test Point 1 1/4" BSP
48 4914.03.000 Adjustable Elbow 1 3/8" BSP - 3/8" BSP
49 7307.01.000 Edging Strip 2 (/metre)
50 5400.01.000 Diode 1 Paired with Item #37
51 55498.02.000 Hill Start Switch 1
52 55327.01.000 Reverse Horn 1
53 - Knob Steering Wheel 1 As part of Item # 7
54 7804.01.002 Signal Conditioning Module 1
55 42379.00 Rubber Clamp Pipe 1
56 6211.05.014 Bolt - Hex Head 2 M5 x 14 (Modify )
57 7804.01.001 Steering Sensor 1
58 55508.06.000 Red LED Indicators 2
59 55508.07.000 Yellow LED Indicators 2
60 42315.00 Dashboard Fascia 1
61 41338.05 Steering Cowl 1 Zapi MIDI only
62 41378.01 Cowl Reinforcement 1 Part of Item #61
63 6121.08.035 Screw - Cap Head 4 M8 x 35
64 7598.04.000 Handle 2
65 - Plug 4 As part of item #64
66 6111.10.040 Bolt - Hex Head 4 M10 x 40
Flexi G4
Hydraulic System

Steering Cover & Dash (A353-3A-00)
fig. A353-3A-00: Steering Column Module - Steering Cover & Dash
Parts List
1 55508.07.000 Yellow LED Indicator 2

2 55508.06.000 Red LED Indicator 2
3 55481.01.003 Electronic Display 1
4 6121.08.035 Screw - Cap Head 4 M8 x 35
5 7598.04.000 Handle 2
6 55498.02.000 Hill Start Switch 1
7 42026 Sticker - Hill Start 1
8 41338.05 Steering Cowl 1
9 42315 Dashboard Fascia 1
28
A354
Brake System
A354-1A - Pedal Plate Module …………………………….…………. p30

A354-2A - Rear Wheel Assembly ……………………………………. p31
A354-3A - Brake Backplate Assembly ………………………………. p32
Flexi G4
Brake System
Pedal Plate Module (A354-1A)
fig. A354-1A: Pedal Plate Module, Exploded View
Parts List
1 41297.04 Pedal Mounting Plate 1

2 55481.01.001 Accelerator Pedal Unit 1 Part of Traction Panel Kit
3 - Accelerator Rubber 1
4 41296.03 Brake Pedal 1
5 55215.07.000 Brake Pedal Rubber 1
6 41291.01 Brake Push Rod 1
7 7197.04.000 Brake Master Cylinder 1
8 CA829802 Micro Switch 1 Traction Cut-out
9 7081.01.000 Expansion Spring 1
10 41297.1 Cable Guard 1
11 7625.01.000 Bush - Glacier 2
12 6121.06.020 Screw - Cap Head 2 M6 x 20
13 6121.08.025 Screw - Cap Head 2 M8 x 25
14 6221.08.035 Screw - Cap Head 1 M8 x 35
15 6110.08.000 Washer - Flat 3 M8
16 6131.08.000 Nut - Nyloc 4 M8
17 6111.10.020 Screw - Setscrew 2 M10 x 20
18 6120.10.000 Washer - Spring 2 M10
19 6221.12.030 Screw - Cap Head 1 M12 x 30
20 6211.12.090 Bolt - Hex Head 1 M12 x 90
21 6111.12.000 Nut - Plain 1 M12
22 6131.12.000 Nut - Nyloc 1 M12
23 6114.02.000 Nut - Plain 1 5/16" UNF
30
Brake System
Rear Wheel Assembly (A354-2A)
fig. A354-2A: Rear Wheel Assembly, Exploded View
Parts List
00 7738.11.000 Brake Back Plate Assembly 1 Lefthand; See A354-3A

00 7738.10.000 Brake Back Plate Assembly 1 Righthand; See A354-3A
01 - Hub Rear Assembly 1
1 7738.08.000 Brake Cable 2
2 7738.08.002 Clip 2
3 6566.06.000 Grease Nipple - Angled 2 M6 45°
4 6171.14.040 Bolt - Durlock 12 M14 x 40
5 4998.01.000 O-ring 2 ø75 x ø105 x 13mm
6 7624.01.000 Taper Roller Bearing 2 32013
7 41278.00 Rear Hub 2 6"
8 7624.02.000 Taper Roller Bearing 2 32010 50 x 80 x 20
9 4998.06.000 Nut - Lock 2 M45 x 1-5mm
10 4998.07.000 Washer - Lock 2 MB9 45mm
11 41293.00 Grease Cover 2
12 6120.06.000 Washer - Spring 12 M6
Screw - Countersunk Socket
14 6131.06.012 6 M6 x 12
Head
15 7635.09.000 Tyre - Rear 2 Plain Rubber 18" x 6"
Flexi G4
Brake System
Brake Backplate Assembly (A354-3A)
fig. A354-3A: Brake Backplate Assembly, Exploded View
Parts List
1 - Brake Backplate R/H 1

1 - Brake Backplate L/H 1
2 7738.12.000 Adjuster 2 Manual
3 7738.07.001 Cylinder - Wheel 2
4 - Common Shoe * 2
5 7738.07.005 Tension Spring 4
6 7738.07.006 Tension Spring 2
7 7738.07.007 Spring 4
8 - Lefthand Shoe * 1
8 - Righthand Shoe * 1
9 7738.07.010 Bracket Spring 4
10 - Fixed Slice 4
11 6111.06.016 Bolt - Hex Head 4 M6 x 16
12 6120.06.000 Washer - Spring 4 M6
13 7738.07.008 Bleed Nipple 2
15 7738.07.012 Nordlock Washer 2 M12
* - 7738.07.009 Brake Shoe Kit 1 Includes:

2 x No-4 - Common Shoe
1 x No-8 - Left Hand Shoe
1 x No-8 - Right Hand Shoe
32
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). p39
A355-2A - Wiring Looms …………………………………………………. p40
Flexi G4
Control System
Control System
Electrical Module - Zapi Traction (A355-1B)
fig. A355-1B-1: Electrical Module - Zapi Traction
34
Control System
fig. A355-1B-2: Electrical Module - Zapi Traction Components
Flexi G4
Control System
Parts List
00 - Zapi Controller Assembly 1

1 41283.03 Backplate 1
2 6211.06.030 Bolt - Hex Head 6 M6 x 30
3 6120.06.000 Washer - Spring 10 M6
4 6110.06.000 Washer - Flat 10 M6
5 55522.02.002 Traction Controller 1 AC3 Truck Serial No Required
6 55327.01.000 Audiable Alarm 1 Reverse Horn
7 6211.06.016 Bolt - Hex Head 10 M6 x 16
8 - Contactor Mounting Bracket 1
9 6211.05.012 Bolt - Hex Head 2 M5 x 12
10 C5188.04 Terminal Block 1
12 55522.02.005 Negative Terminal Post 1
14 6120.04.000 Washer - Spring 2 M4
15 6110.04.000 Washer - Flat 2 M4
16 55370.10.000 Relay Holder Blue 2
17 6211.03.030 Bolt - Hex Head 4 M3 x 30
18 6111.03.000 Nut 4 M3
19 5849.02.000 11-pin Relay 2 48V
20 55370.09.000 Timer Relay 2
21 - Fuse Holder 3
23 55097.04.000 Fuse 1 5A
24 55201.01.000 Fuse 2 10A
25 - Fuse Holder Mounting Bracket 1
26 - Washer - Flat 2
27 55490.02.000 K4 Contactor 1 SW200-421 48V
28 55490.06.000 K6 Contactor 1 SW200-261 48V
29 - Contactor Mounting Bracket 1
31 55427.03.000 Load Resistor 1 120Ω 50W
32 55444.07.000 Fuse Holder 3
33 - Fuse Mounting Plate 1
34 55096.01.000 Fuse 2 400A
35 5367.01.000 Fuse 1 100A
36 55490.01.000 K5 Contactor 1 SW80B-10 48V
37 - Cable Line 1 1 K4 to Fuse
40 - Cable Line 4 1 Fuse to Traction Contactor
41 - Cable Line 5 1 Traction Contactor to Negative Post
42 55450.01.000 Temperature Switch 1
43 6211.03.010 Bolt - Hex Head 4 M3 x 10
44 - K5 Label 1
45 - K4 Label 1
46 - K6 Label 1
47 - K9 Label 1
48 - K10 Label 1
49 6120.08.000 Washer - Spring 5 M8
50 6111.08.000 Nut 3 M8
51 6110.08.000 Washer - Flat 11 M8
52 6110.08.000 Washer - Flat 5 M8
53 6210.10.030 Bolt - Hex Head 1 M10 x 30
54 6111.10.000 Nut 3 M10
55 42090.01 Cable Line 6 1
57a - 48V Pin 1
55385.12.000 Battery Plug Female 1 Female Plug / Male Pins

57b - 55385.13.000 Battery Plug Male 1 Male Plug / Female Pins
55385.14.000 Battery Plug Handle 1
36
Control System
Solenoid Switches (A355-1B-00)
fig. A355-1B-00: Solenoid Switches K4 & K6 fig. A355-1B-00: Solenoid Switch K5
Parts List
K4 Contactor - SW200-421 - Bypass / Hydraulic Lift Contact

1 55490.02.000 K4 Complete 1 Includes Items 2 - 12
2 - Top Cover 1
3 - Fixing Screws 2
4 - Contact Fixtures 2 See Item #12
5 - Return Spring 1 See Item #12
6 - Fixed Contact 2 See Item #12
7 - Moving Contact 1 See Item #12
8 - Top Cover Base 1
9 - Plunger 1 See Item #12
10 - Coil & Magnet 1
11 - End Cap 1
12 55490.02.100 Contact Tip Kit 1 Includes; 4, 5, 6, 7, 9
K5 Contactor - SW80B-10 - Steer Contact
13 55490.01.000 K5 Complete 1 Includes Items 14 - 21
14 - Top Cover 1
15 - Fixing Screws 2
16 - Contact Fixtures 2
17 - Return Spring 1 See Item #21
18 - Fixed Contact 2 See Item #21
19 - Moving Contact 1 See Item #21
20 - Coil & Magnet 1 See Item #21
21 55490.01.100 Contact Tip Kit 1 Includes; 17, 18, 19, 20
K6 Contactor - SW200-261 - Steer Contact
As K4, except:
1 55490.06.000 K6 Complete 1
12 55490.06.100 Contact Tip Kit 1
Flexi G4
Control System
Reverse Alarm Kit (A355-1B-01)
fig. A355-1B-01: Reverse Alarm Kit
Parts List
1 - 55327.01.000 Audible Alarm 1

2 - - Cables 2
3 - 6607.01.000 Screw - Taptite 2 M4 x 6 Taptite
4 - 6621.01.000 Washer - Flat 2
5 - 6111.03.000 Nut - Plain 4 M3
38
Control System
Cold Store Additions (Electrical) (A355-1B-02)
Parts List
1 - 55197.06.000 Fuse Terminal 1

2 - 55201.01.000 Fuse 10A 1
3 - 55415.01.000 Resistor 33Ω 100W 3
4 - 55209.01.000 Resistor 100Ω 50W 2
5 - 55427.09.000 Resistor 150Ω 25W 3
6 - 55468.02.000 Thermostat 1 RS159-2099
7 - 5940.01.000 SW80 24V Solenoid Switch 1 24V
8 - 55115.01.000 Suppressor 1
Cold Store Additions (Solenoid SW80) (A355-1B-02b)
fig. A355-1B-02b: Cold Store Additions - Solenoid SW80; Exploded View
Parts List
00 - 5940.01.000 SW80 Complete 0 24V

1 - - Top Cover 1
2 - - Fixing Screws 2
3 - - Contact Fixtures 2 See Item #9
4 - - Return Spring 1 See Item #9
5 - - Fixed Contact 2 See Item #9
6 - - Moving Contact 1 See Item #9
7 - - Coil & Magnet 1
8 - 5618.01.000 Auxiliary Terminal Block 1 See Item #9
9 - 55490.01.100 Contact Tip Kit 1 Includes; 3, 4, 5, 6, 8
Flexi G4
Control System
Wiring Looms (A355-2A)
fig. A355-2A: Truck Wiring Looms
40
Control System
Wiring Looms (A355-2A)
Parts List
1 - 42035.00 Main Wire Loom - Truck 1

2 - 41883.01 Wire Loom 1 Short H / B Switch Loom
3 - 41883.02 Wire Loom 1 Short Spool M / Switch Loom
4 - 41323.03 Wire Loom 1 To Lift / Tilt and Steer Motors
5 - 42035.31 Wire Loom 1 Hillstart Push Button
6 - 42082.00 Wire Loom - Panel 0 Included on Panel (not shown)
7 - 41323.05 Heavy Cable No2 1 Line Contactor - Fuse
8 - 41323.06 Heavy Cable No20 1 Steer & Lift / Tilt Motor Link
9 - 41323.07 Heavy Cable No20 1 Steer Motor - Main
10 - 41323.08 Heavy Cable P2 1 Lift / Tilt Motor - K4
11 - 41323.09 Heavy Cable P4 1 Steer Motor - K5
12 - 42342.15 Traction Motor Cable 1
15 - - - - -
16 - - - - -
17 - 41883.17 Wire Loom (Keycode Switch) 1 To Keyswitch & Horn
18 - 41323.18 Optional Wire Loom 1 Keycode System
19 - 41323.20 Wire Loom 2 Fan Lead
20 - 41323.21 Wire Loom 1 Horn Push Button
21 - 41323.22 Wire Loom 1 Horn
22 - 41323.23 Wire Loom 1 Reverse Alarm
23 - 55523.01.006 Sensor Cable 1 To Encoder & Temperature Sensor
24 - 41883.25 Wire Loom 1 Fwd / Rev Lever
25 - 41323.26 Wire Loom 1 Battery Cable - Panel / Male
26 - 41323.27 Wire Loom 1 Battery Cable - F / F
Flexi G4
42
A356
Mast System
A356-1A - Mast Support Assembly ………......…………………................. p44

A356-2A - Mast Assembly ………………………………………................... p46
A356-3A - Mast Fitting ……………………………………………................. p47
A356-3A-01 - Fixed Stage Assembly ........................................... p48
A356-3A-02 - Second Stage Assembly ....................................... p50
A356-3A-03 - Third Stage Assembly ........................................... p52
A356-4A - Narrow Aisle Fork Carriage Assembly ………………................ p54
A356-4A-00 - Alternate Fork Carriage Assembly ......................... p55
A356-5A - Narrow Aisle Hydraulic Components Fixed Stage …................ p56
A356-6A - Narrow Aisle Hydraulic Components Third Stage .................... p59
Flexi G4
Mast System
Mast Support Assembly (A356-1A)

fig. A356-1A: Mast Support Assembly, Exploded View
44
Mast System
Mast Support Assembly (A356-1A)

Parts List
1 41249.05 Mast Support Fabrication 1

2 41424.01 Slewing Ring 1
3 6711.12.075 Set Pin - Hex Head 47 M12 x 75 Grade 10-9
4 - Mast Support Clamp 2 Right, part of item #1
5 6221.20.090 Screw - Cap Head 4 M20 x 90
6 6120.20.000 Washer - Spring 4 M20
7 6566.04.000 Grease Nipple 2 M10
8 7626.01.000 Bush - Glacier 2 Mast
9 41343.01 Mast Retaining Washer 2
10 6120.10.000 Washer - Spring 2 M10
11 6121.10.030 Screw - Cap Head 2 M10 x 30
13 7629.03.000 Rubber Buffer 2
14 6588.01.000 Circlip 1
15 6591.01.000 Spring Clip 4
16 6110.24.000 Washer - Flat 4 M24
17 44030.xx.000 Cylinder - Tilt 2
18 3526.03 Tilt Cylinder Mounting Shaft 4
20 - Spindle 1
21 4521.01.000 O-ring 8 1/4" BSP Dowty
22 6211.14.065 Bolt - Hex Head 2 M14 x 65
23 6111.14.000 Nut 2 M14
24 7627.01.000 Thrust Washer 2 Glacier
25 - Connector 90 2 1/4" BSP - 1/4" BSP Elbow
27 4439.01.000 Blanking Plug 2 1/4" BSP
28 41249.24 Bearing Seat 1 Part of item #1
29 41249.21 Articulation Shaft 1
30 6120.16.000 Washer - Spring 4 M16
32 - Mast Support Clamp 1 Left, part of item #1
33 6566.10.000 Grease Nipple 5 M10
34 6211.05.014 Bolt - Hex Head 2 M5 x 14
35 - Rubber Clamp Pipe 1
36 - Hose Fixed Seat 1
Flexi G4
Mast System
Mast Assembly (A356-2A)

fig. A356-2A: Mast Assembly, Exploded View
Parts List
30772A 3912mm
30773A 4521mm
31190 4800mm
Mast Sub-Assembly Fixed
30774A 4928mm
1 - Stage 1
3157D 5550mm
(Outer)
30770A 6600mm
30771A 7410mm
30158 8400mm
30778A 3912mm
30779A 4521mm
31191 4800mm
Mast Sub-Assembly Second
30780A 4928mm
2 - Stage 1
30173 5550mm
(Middle)
30776 6600mm
30777 7410mm
30159 8400mm
30184A 3912mm
30785A 4521mm
31192 4800mm
30786A Mast Sub-Assembly Third Stage 4928mm
3 - 1
30185 (Inner) 5550mm
30782 6600mm
30783 7410mm
30160 8400mm
46
Mast System
Mast Fitting (A356-3A)

fig. A356-3A: Mast Fitting - Full Assembly, Exploded View
Parts List
B350615 3912mm
B350618 4050mm
B350607 4200mm
B350616 4521mm
B351030 4620mm
B350608 4800mm
B350617 4928mm
B351025 5010mm
B351391 5220mm
B351031 5400mm
B350606 5550mm
B350622 6000mm
00 B351026 - Full Mast Assembly 1 6210mm
B350609 6600mm
B351027 7020mm
B351028 7200mm
B350610 7410mm
B350611 7620mm
B351029 8010mm
B350620 8204mm
B350612 8220mm
B350613 8400mm
B350614 8610mm
B351032 8820mm
B350621 9000mm
Flexi G4
Mast System

Fixed Stage Assembly (A356-3A-01)
fig. A356-3A-01: Mast Fitting - Fixed Stage, Exploded View
Parts List
Ref UK Pt.No Description Qty Notes
1 - Washer - Flat n M10 2t

2 7629.04.000 Rubber Buffer 2 0
3 6110.10.000 Washer - Flat 2 M10
4 6121.10.040 Screw - Cap Head 2 M10 x 40
5 6131.10.000 Nut - Nyloc 4 M10
48
Mast System

Fixed Stage Assembly (A356-3A-01)
Parts List (cont-)

6 41410.00 Cylinder Clamp 2 0
7 6121.10.045 Screw - Cap Head 4 0
4200mm
5010mm
5550mm
6000mm
Leaf Chain
6600mm
8 41410 2
7020mm
- To Third Stage Mast, Lower
7620mm
8010mm
8610mm
9000mm
9 6353.01.000 Split Pin 4 0
10 7694.03.000 Chain Anchor Pin 2 8234-09
11 7694.02.000 Chain Anchor Bolt 2 BL0534 MB1
12 6111.16.000 Nut - Plain 2 M16
13 6131.16.000 Nut - Nyloc 2 M16
14 40558.06 Limit Switch Bracket 1 0
55219.02.000 Limit Switch 1 0
15
55219.03.000 0.00 1 0
16 6121.04.016 Screw - Cap Head 2 M4 x 16
17 6120.06.000 Washer - Spring 2 M6
19 41451.11 Bulkhead Bracket 1 0
20 6120.06.000 Washer - Spring 2 M6
4200mm
5010mm
5550mm
6000mm
Cylinder - Main Lift 6600mm
21 41404.xx 2
(Fixed Stage) 7020mm
7620mm
8010mm
8610mm
9000mm
22 6566.06.000 Grease Nipple - Angled 2 M6 45°
23 4143.00 Manifold 1 0
24 6120.08.000 Washer - Spring 2 M8
25 6121.08.020 Screw - Cap Head 2 M8 x 20
6596.01.000 Shim Standard 40 ID x 0-5
26 n
6596.03.000 0.00 Heavy Duty
7671.01.000 Roller Assembly Standard
27 4
7773.01.000 0.00 Heavy Duty
28 6161.10.010 Grubscrew 2 M10 x 10
29 - - - -
30 41396.xx Fixed Stage Mast Fabrication 1 Mast Ref number Required
For UK Masts replace .XX
LIFT HEIGHT .XX
4200 04
5010 08
5550 01
6000 13
6600 16
7020 18
7620 21
8010 23
8610 26
9000 28
Flexi G4
Mast System

Second Stage Assembly (A356-3A-02)
fig. A356-3A-02: Mast Fitting - Second Stage, Exploded View
50
Mast System

Second Stage Assembly (A356-3A-02)
Parts List
Parts List
6596.01.000 Standard 40 ID x 0-5

1 Shim n
6596.03.000 Heavy Duty
7671.01.000 Standard
2 Roller Assembly 4
7773.01.000 Heavy Duty
3 40558.03 Reaction Block 1 -
4 6131.06.025 Setscrew - Countersunk 2 M6 x 25
5 6150.30.000 Washer - Flat 2 M30 Light
6 40149 Hose Pulley 2 -
7 40206 Bearing Spacer 3 -
8 40148.01 Chain Pulley 2 -
9 7672.01.000 Pulley Bearing 2 6306-2RS
10 6428.01.000 Circlip 2 72mm Internal
11 3169.35.000 Spacer 1 -
12 41408.01 Hose Pulley 1 -
14 41409 Pulley Shaft 1 2 30 OD x 112 BSP
15 6120.08.000 Washer - Spring 2 M8
16 6111.08.016 Setscrew 2 M8 x 16
17 0 Second Stage Mast Fabrication 1 Mast Ref number required
Flexi G4
Mast System

Third Stage Assembly (A356-3A-03)
fig. A356-3A-03: Mast Fitting - Third Stage, Exploded View
Parts List
1 - Washer - Flat n M10 2t

2 7629.04.000 Rubber Buffer 2 0
3 6110.10.000 Washer - Flat 2 M10
4 6121.10.035 Screw - Cap Head 2 M10 x 35
5 6111.10.016 Screw - Cap Head 2 M10 x 16
6 6120.10.000 Washer - Spring 2 M10
7 41409.01 Pulley Shaft 2 2 0
52
Mast System

Third Stage Assembly (A356-3A-03)
Parts List (cont-)
Parts List (cont-)

4200mm
5010mm
5550mm
6000mm
7694.01.000
6600mm
8 Leaf Chain 2
7020mm
(length as required)
7620mm
8010mm
8610mm
9000mm
9 6353.01.000 Split Pin 8 -
10 7694.03.000 Chain Anchor Pin 4 8234-09
11 7694.02.000 Chain Anchor Bolt 4 BL0534 MB1
12 6111.16.000 Nut - Plain 4 M16
13 6131.16.000 Nut - Nyloc 4 M16
15 41407 Chain Pulley 2 -
16 7672.01.000 Pulley Bearing 2 6306-2RS
17 6428.01.000 Circlip 2 72mm Internal
18 40206.02 Bearing Spacer 2 -
19 41408 Hose Pulley 2 -
20 6120.08.000 Washer - Spring 2 M8
21 6111.08.016 Setscrew 2 M8 x 16
4200mm
5010mm
5550mm
6000mm
Cylinder - Free Lift 6600mm
22 41405.xx 2
(Third Stage) 7020mm
7620mm
8010mm
8610mm
9000mm
23 6161.08.010 Grubscrew 2 M8 x 10
24 41406 Pulley Yoke 2 -
25 6161.08.020 Grubscrew 4 M8 x 20
6596.01.000 n Standard 40 ID x 0-5
26 Shim
6596.03.000 0 Heavy Duty
7671.01.000 4 Standard
27 Roller Assembly
7773.01.000 0 Heavy Duty
28 41410.01 Cylinder Clamp 2
29 6131.08.000 Nut - Nyloc 4 M8
31 0 Third Stage Mast Fabrication 1 Mast Ref number required
Flexi G4
Mast System
Narrow Aisle Fork Carriage Assembly (A356-4A)

fig. A356-4A: Bolzoni Fork Carriage Assembly, Exploded View
Parts List
1 41411.xx Side-Shift 1 Bolzoni 860mm

7671.01.000 Roller Assembly 4 Standard
2
7773.01.000 0.00 0 Heavy Duty
3 7694.02.000 Chain Anchor Bolt 2 BL 0534 MB1
4 7694.03.000 Chain Anchor Pin 2 8234-09
5 6111.16.000 Nut - Plain 2 M16
6 6131.16.000 Nut - Nyloc 2 M16
7 6353.01.000 Split Pin 2 -
6596.01.000 Shim n Standard 40 ID x 0-5
8
6596.03.000 0.00 0 Heavy Duty
9 41936.03 Fork 2 1150 mm
10 6566.06.000 Grease Nipple 4 M6
11 6121.16.025 Screw - Cap Head 1 M16 x 25
12 6120.16.000 Washer - Spring 1 M16
13 6121.08.012 Screw - Cap Head 1 M8 x 12
14 6120.08.000 Washer - Spring 1 M8
15 4997.21.005 Upper Wear Pad - Right 1 -
16 4997.21.004 Upper Wear Pad - Left 1 -
17 4997.21.002 Lower Wear Pad - Right 1 -
18 4997.21.003 Lower Wear Pad - Left 1 -
19 4997.21.001 Cylinder - Side-shift 1 -
54
Mast System
Narrow Aisle Fork Carriage Assembly (A356-4A)

Alternative Fork Carriage Assembly (A356-4A-00)
fig. A356-4A-00: Kaup Fork Carriage Assembly, Exploded View
Parts List
1 - Mast Carriage Assembly 1 Kaup Standard Mast

2 - Fork Carriage 1 Kaup Heavy Duty
3 4997.44.023 Bush - Glacier 2 -
4 4997.44.025 Groove Ring 2 -
5 4997.44.022 Washer 2 -
6 4997.44.024 Stripper 2 -
7 4997.44.004 Piston Rod 2 -
8 4997.79.001 Holder 2 -
9 6121.12.060 Screw 2 M16 x 60
10 4997.44.019 Guide Roller 2 0
11 4997.44.035 Nut 4 M30
12 4997.44.033 Grease Nipple 2 M8
13 4997.44.005 Sliding Piece 13 or 13a
4
13a 4997.44.06 0.00 0
14 4997.44.032 Grease Nipple 2 M8
15 6121.12.030 Stop Bolt 2 -
16 6120.16.000 Washer - Spring 1 M16
17 6121.16.025 Screw - Cap Head 1 M16 x 25
18 41936.03 Fork 2 1150 mm
7671.01.000 Roller Assembly Standard
19 4
7773.01.000 0.00 Heavy Duty
20 - Chain Anchor Assembly 2 -
Flexi G4
Mast System
Narrow Aisle Hydraulic Components - Fixed Stage (A356-5A)

Important:
- All masts are stamped either UK or TW, please state when ordering parts.
fig. A356-5A: Narrow Aisle Hydraulic Components - Fixed Stage, Exploded View
Parts List
4200mm
4620mm
4800mm
5010mm
5400mm
5550mm
6000mm
6210mm
6600mm
See Note A
1 Free Lift Feed Pipe 1 7020mm
(page 58)
7200mm
7410mm
7620mm
8010mm
8220mm
8400mm
8610mm
8820mm
9000mm
56
Mast System
Parts List (cont-)

4200mm
4620mm
4800mm
5010mm
5400mm
5550mm
6000mm
6210mm
6600mm
2 41441.xx Main Lift Feed Pipe 1 7020mm
7200mm
7410mm
7620mm
8010mm
8220mm
8400mm
8610mm
8820mm
9000mm
4200mm
4620mm
4800mm
5010mm
5400mm
5550mm
6000mm
6210mm
6600mm
3 41442.xx Main Lift Feed Pipe 1 7020mm
7200mm
7410mm
7620mm
8010mm
8220mm
8400mm
8610mm
8820mm
9000mm
4200mm
4620mm
4800mm
5010mm
5400mm
5550mm
6000mm
6210mm
6600mm
See Note B
4 Side-Shift Feed Pipe 1 7020mm
(page 58)
7200mm
7410mm
7620mm
8010mm
8220mm
8400mm
8610mm
8820mm
9000mm
Flexi G4
Mast System
Parts List (cont-)

4200mm
4620mm
4800mm
5010mm
5400mm
5550mm
6000mm
6210mm
6600mm
See Note C
5 Side-Shift Feed Pipe 1 7020mm
(below)
7200mm
7410mm
7620mm
8010mm
8220mm
8400mm
8610mm
8820mm
9000mm
6 Manifold 1 Also see A356-3 Item #23
7 4971.05.000 Safety Valve 1 0.00
8 - Blanking Plug 1 0.00
9 4627.04.000 Pipe Clamp 3 8mm Twin
10 44057.12.000 Connector - Male 2 1/2" BSP - 15mm
11 44057.13.000 Bulkhead Coupling 1 15mm
12 44057.14.000 Connector - Male 4 3/8" BSP - 10mm
13 44057.15.000 Connector 2 8mm
5500mm
Free Lift Rubber Hose 6600mm
14 41452.xx 1
Assembly 7620mm
8610mm
5500mm Also see
Side-Shift Rubber Hose 6600mm A356-6
15 41453.xx 2
Assembly 7620mm Item #4
8610mm
16 41451.11 Bulkhead Bracket 1 0.00
17 4627.05.000 Pipe Clamp 4 15mm Single
18 6111.08.020 Setscrew 2 M8 x 20
20 6111.06.016 Bolt - Hex Head 2 M6 x 16
21 6120.08.000 Washer - Spring 2 M8
22 4245.03.000 Rupture Valve - Set to 1-2mm 2 3/8" Part of Free Lift Cylinder
23 6120.06.000 Washer - Spring 2 M6
24 - Spring 1 0.00
25 - O-ring 1 0.00
26 - Circlip 1 0.00
27 41437.00 Manifold 1 Also see A356-3 Item #23
28 - Connector 1 0.00
29 - - - -
30 - - - -
31 - Plug 1 0.00
32 - Ring 1 0.00
Coned-stud Adapter
33 - 44095.01.000 1 Required to connect a mast stamped
(Not Shown)
with TW to an NA truck chassis ONLY.
41522.xx Free Lift Feed Pipe 1

44063.04.000 Walform Seal (15mm) 2 All four items required as NA equivelant
A See Item #1
44057.16.000 Straight Coupling (15mm) 1 to TW item #1
41484.xx Free Lift Feed Pipe 1
41523.xx Sideshift Feed Pipe 1
B See Item #4
C See Item #5
58
Mast System
Narrow Aisle Hydraulic Components - Third Stage (A356-6A)

fig. A356-6A: Narrow Aisle Hydraulic Components - Third Stage, Exploded View
Flexi G4
Mast System
Narrow Aisle Hydraulic Components - Third Stage (A356-6A)
Parts List
5500mm
6600mm
1 41487.xx Side-shift Feed Pipe 1
7620mm
8610mm
5500mm
6600mm
2 41488.xx Side-shift Feed Pipe 1
7620mm
8610mm
5500mm
6600mm
3 41454.xx Side-Shift Hose - Secondary 2
7620mm
8610mm
5500mm Also See
6600mm A356-5
4 41453.xx Side-Shift Hose - Primary 2
7610mm Item #15
8610mm
5 C Bulkhead Coupling 3 8mm
6 - Nut - Lock 4 0.00
5500mm
6600mm
7 41452.xx Rubber Hose 1
7620mm
8610mm
8 - Feed Pipe 1 0.00
9 - Rubber Hose 1 0.00
11 44057.13.000 Bulkhead Coupling 2 15mm
12 - Connector - Elbow 3 To A356-3-03 #22
14 - Connector - T 1 To A353-1A #19 & A356-3-03 #22
15 - Pipe 1 8mm diameter
16 - Connector - Elbow 3 0.00
17 - Pipe Clamp 2 0.00
18 - Nut 1 0.00
19 4521.01.000 O-ring 2 1/4" BSP Dowty
20 4976.01.000 Nylon Pipe 1 8mm diameter (/metre)
21 - - - -
22 6211.08.016 Bolt - Hex Head 2 M8 x 16
23 6120.08.000 Washer - Spring 2 M8
60
A357
Accessory System
A357-1A - Labels ..……………………………….………………………… p62

A357-2A - Seal Kit …………………………….…………………………… p64
A357-3A - Cold Store Additions (Mechanical) ..…………………………. p64
Flexi G4
Accessory System
Labels (A357-1A)
fig. A357-1A-1: Labels
fig. A357-1A-2: Label Locations 1
62
Accessory System
Labels (A357-1A)
Parts List
1 Capacity Plate 40222-36 1 Printed by Design dept

- - - - -
2 Warning Label 40084-69 1 General Operation
3 Warning Label 40084-00 2 Hand Crush - Side Force
4 Warning Label 40084-01 2 Foot Crush - Side Force
5 Warning Label 40084-70 1 Tip Over
6 Warning Label 40084-04 2 Overheads Loads
7 Warning Label 41344-?? 1 Seat Lift
8 Warning Label 41431-?? 1 Battery Retainers
- - - - -
9 Instruction Label 40084-12 1 Lifting Points
10 Instruction Label 40113-03 1 Pedal Functions
11 Instruction Label 40129-00 1 Transmission Oil Fill Point
12 Instruction Label 40129-01 1 Hydraulic Oil Fill Point
13 Instruction Label 40155-03 1 Battery Charge Label
14 Instruction Label 7207.01.00 4 Lifting Points
15 Instruction Label 41579-00 1 Horn Symbol
16 Instruction Label 41930-00 1 Light Symbol
17 Instruction Label 42026-00 1 Hillstart Symbol
- - - - -
18 Decal - Flexi Logo 7618.09.000 1 Set w/out flashes
- - - - -
19 Instruction Label 40084-71 1 Battery Charge Label
Flexi G4
Accessory System
Seal Kit (A357-2A)
Parts List
41404.200 GKN
1 B350738 41404.300 Seal Kit - Main Lift Cylinder 2 Tail Lift
41404.400 Rangers
41405.200 GKN
2 B350739 41405.300 Seal Kit - Free Lift Cylinder 2 Tail Lift
41405.400 Rangers
44030.14.001 TW
3 B350740 Seal Kit - Tilt Cylinder 2
44030.04.002 NA
4997.21.006 Standard
4 B350802 Seal Kit - Sideshift Cylinder 1
4997.21.010 Cold Store
5 - 4997.44.017 Seal Kit - Sideshift Cylinder(for A 2 Seal Kit A
6 - 4977.03.000 Seal Kit - Spool Valve Assebly 1 Seal Kit
Cold Store Additions (Mechanical) (A357-2A)
Parts List
1 - 3735-03 Axel Pivot Shaft 1

2 - 3526-05 Tilt Cylinder Mounting Shaft 4
3 - - Cold Store Grease a/r Shell Alvania RA
4 - - Transmission Oil 0.8 Litre, Aral Degol PAS150
5 - - Hydraulic Oil 50 Litres, Mobil Aero HFACastrol Hyspin AWH-1-5
6 - 55413.03.000 Low Temperature 4 Core 6m Igus CF9.10.04
7 - 41715.01 Traction Motor Brush Cover 1
8 - 41715.02 Traction Motor Brush Cover 1
9 - 0.00 Air Sentry 1 MP Filtri No. D-101
10 - 0.00 Air Sentry Adaptors 2 MP Filtri No. A-103
11 - TB194 Technical Bulletin ref
64
A358
Index
A358-1A - By Part Name .…………………………………………................ i

A358-2A - By Part Reference Number - NA .……………………............. xiii
A358-3A - By Part Reference Number - TW ..………………..……........ xxiii
ssue E
Flexi G4
1
oved
allan
allan
allan
3
Flexi G4
5
Flexi G4
7
9
Flexi G4
11
Flexi G4
13
Flexi G4
15
Flexi G4
17
19
Flexi G4
21
Flexi G4
23
Flexi G4
25
Flexi G4
27
29
Flexi G4
31
33
Flexi G4
35
Flexi G4
37
Flexi G4
39
Flexi G4
41
43
Flexi G4
45
Flexi G4
47
Flexi G4
49
Flexi G4
51
Flexi G4
53
Flexi G4
55
Flexi G4
57
Flexi G4
59
Flexi G4
61
Flexi G4
63
65

Flexi G4 AC Parts Manual

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Flexi G4 AC Parts Manual

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Flexi G4

A351 - Transmission System 3

A352 - Chassis Fitting System 9

A353 - Hydraulic System 19

A354 - Brake System 29

A355 - Control System 33

A356 - Mast System 43

A357 - Accessory System 61

Document Revision Details (A350-1A)

Rev Date Revised By Description Appro

A 14 / 03 / 2013 H Clemmet First Issue P Ca

A351-1A - Front Axle Assembly ………………………………………. p4

Front Axle Assembly (A351-1A)

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

Ref TW Pt No NA Pt.No Description Qty Notes

00 B350686 7661.09.000 Front Wheel Assembly 2 Contains reference parts 1 & 2

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

Ref TW Pt No NA Pt.No Description Qty Notes

00 B350603 4978.15.000 Transmission Assembly 1 Parts: All excluding 51

A352-1A - Chassis Kit ..................................................................... p10

Chassis Fitting System

Chassis Kit (A352-1A)

fig A352-1A: Chassis Kit, Exploded View

Chassis Kit (A352-1A)

Ref TW Pt No NA Pt.No Description Qty Notes

00 - - Steering Motor Extension 1 See List A352-1A-1

Chassis Fitting System

Chassis Kit (A352-1A)

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

Ref TW Pt No NA Pt.No Description Qty Notes

1 M1401-M12*40 6121.12.040 Screw - Cap Head 8 M12 x 40

Chassis Kit (A352-1A)

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

Ref NA Pt.No Description Qty Notes

1 41265.17 Chassis Fabrication 1 Pallet Trick Batt. Removal

Chassis Fitting System

Seat and Covers (A352-2A)

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

Seat and Covers (A352-2A)

Ref NA Pt.No Description Qty Notes

1 41339.01 Battery Lid 1

Overhead Guard (A352-3A)

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

Ref NA Pt.No Description Qty Notes

1 41268.10 Overhead Guard 1

Battery Tray Assembly (A352-4A)

fig. A352-4A: Battery Tray Assembly

Ref TW Pt No NA Pt.No Description Qty Notes

1 34948 41369.30 Battery Tank 1

Controls Assembly (A352-5A)

fig. A352-5A: Controls Assembly

Ref NA Pt.No Description Qty Notes

A353-1A - Oil Tank Module……………………………………..……. p20

Oil Tank Module (A353-1A)

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

Oil Tank Module (A353-1A)

Ref TW Pt No NA Pt.No Description Qty Notes

1 30207C 41282.03 Oil Tank 1 Top profile - 41282-05

Oil Tank Module (A353-1A)

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

Ref TW Pt No NA Pt.No Description Qty Notes

1 - 55294.04.001 Drive Endhead 1 H95-003A

Oil Tank Module (A353-1A)

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