Yale GP040MX GP050MX GP060MX Forklift Parts Manual PDF Download

Description

Yale GP040MX, GP050MX and GP060MX Forklift Parts Manual – Document 550141688

This is the illustrated parts manual for the Yale GP/GLP040MX, GP050MX and GP060MX lift trucks built on the A390 design series. It is the reference used to identify and order replacement assemblies, subassemblies and detail parts for these trucks, and it covers gasoline/LP-gas machines as well as the Yanmar diesel variants. Every assembly is shown as an exploded illustration with callouts that tie directly to a parts list carrying the part number, description and quantity required.

File Details

• Manual type: Illustrated Parts Manual
• Brand: Yale
• Models covered: GP040MX, GP050MX, GP060MX, GLP040MX, GLP050MX, GLP060MX
• Design series: A390
• Document number: 550141688
• Language: English
• Page count: 728 pages
• File format: PDF
• Publication date shown: 12/2024
• Related publications listed: Operating Manual 550141626, Service Manual 550141696

Chapters Covered

• Section 1 – General Truck: counterweight, overhead guard, hood assembly, PVC door kit and top screen, front and rear screen kits, steel door assemblies (LH/RH), sliding window kit, cab heater, heater hoses (PSI and Yanmar), non-suspension and full-suspension seats, armrest slider assembly, floorplates and covers (LPG and Bi-Fuel), interior panels and covers, sound abatement, static strap installation, cowl mount, fender extensions, load back rest extension, forks (standard, optional and polished with full bottom taper), nameplates and labels, radiator labels
• Section 2 – Engine Assembly LPG: engine mounting, engine control module mounting, electrical sensors, engine and attaching parts, transmission flex plate, hi-fan assembly, fan assembly, flywheel mounting hardware, cylinder block, cylinder head, camshaft and valves, rocker cover, piston and crankshaft, ignition coil, balancer, starter, alternator, cab heater coolant, exhaust manifold, intake manifold, front cover and oil pan, oil pump and attaching parts, pump mount bracket, dipstick and tube, water outlet, thermostat and DRS circuit, water pump, excluder shield
• Section 3 – Engine Assembly Yanmar: engine mounting, oil pan and flywheel housing, cylinder block, cylinder head, crankshaft and pistons, lubrication system, intake and exhaust manifold, camshaft and drive gear, water separator, injection pump, fuel injection system, water cooling system, gear housing, flywheel mounting hardware, alternator, starter, engine gasket kit
• Section 4 – Exhaust System: overhead exhaust with and without catalytic converter, counterweight exhaust with and without catalytic converter, Yanmar overhead and counterweight exhaust
• Section 5 – Cooling System: PSI standard and anti-clog cooling systems, Yanmar standard and anti-clog without silencer
• Section 6 – Fuel System: air intake, pre-cleaner, single and dual element air filter assemblies, LPG tank and mounting (fixed steel strap and Bi-Fuel), LPG tank bracket (swing-out), LPG tank mounting bracket assembly, fuel regulating system, LPG lock-off, throttle body, mixer/EPR and PCV air hoses, fuel rail, Bi-Fuel fuel system, fuel sender and attaching parts, throttle pedal assemblies (PSI and Yanmar, standard and foot directional control), throttle cable, Yanmar fuel system
• Section 7 – Electrical System: frame electrical arrangement (PSI and Yanmar), harness groups, cowl electrical, controller (E-Hydraulics), power distribution module, load weigh electrical, instrument panel assembly, remote key switch, battery and disconnect switch, battery cables, cab wiring, light group (tail, brake, backup, turn, side marker, work and strobe), blue spotlight with rear work light, harness arrangement for lights, mini-lever controls (three and four function, with and without clamping), cab heater wire harness, cowl harnesses, engine wire harness, hazard light, seat belt and seat belt interlock harnesses, frame harnesses, speed limiter, E-Hydraulics harness, telemetry FM1A and FM1B
• Section 8 – Transmission: transmission cooling, transmission housing and assembly, input/forward clutch, counter/reverse clutch, torque converter housing and attaching parts, inching valve and attaching parts, inching valve assembly
• Section 9 – Drive Axle: drive axle and attaching parts (GP40-50MX early and late, GP60MX), drive axle center section and hub assembly, drive shaft with cover, drive tires and wheels (solid, solid wide, pneumatic, divided solid tire, solid pneumatic 7.00 x 15 rim, solid pneumatic wide 5.00 x 12 rim)
• Section 10 – Steering System: steer axle (both build ranges), steer cylinder, steering column and attaching parts, steer control unit and attaching steer hoses, steer tires and wheels including divided wheel solid tire
• Section 11 – Brake System: brake assembly for GP040-GP050MX and GP060MX, brake linkage single pedal and dual pedal, brake pedal single pedal, park brake attaching parts, park brake assembly, brake master cylinder
• Section 12 – Hydraulic System: hydraulic supply and return (standard and diesel 24cc), hydraulic hoses (three and four function, manual and electro-hydraulic), pump drive assembly, gear pump, hand levers (three and four function, with detent, with RTST), hydraulic control valve manual controls (inlet, lift, tilt, auxiliary, outlet sections), hydraulic control valve E-Hydraulic controls (inlet, lift, tilt, auxiliary, outlet sections), tilt hydraulics and accumulator, tilt cylinder and mast installation, tilt cylinders
• Section 13 – Mast, Two Stage Limited Free-Lift: mast assembly and main lift cylinder for A389 and A399 mast series, header hoses and attaching parts, carriage
• Section 14 – Mast, Three Stage Full Free-Lift: outer mast, intermediate mast and main-lift, inner mast and free-lift for A387 and A397 mast series (both sides of the 8/2017 change), main lift cylinder, free-lift cylinder, header hose and attaching parts, freelift tube group, carriage
• Section 15 – Options: seat belt interlock, return to set tilt group controller, backup alarm, mirrors, altered counterweight with lifting eye, special low overhead guard, document clip, undercarriage screen, strobe light, fire extinguisher, accumulator, auxiliary quick disconnect manifold and hoses, auxiliary tube extensions, integral side-shift carriage and cylinder, rod assembly, bearing kits, fork positioner assembly, telemetry level 1/2/3, card reader, traction speed limiter
• Section 16 – Field Conversion Kits: add-on option and conversion kits, add-on option kits for fork positioner mechanism, high termination extension tubes, control valve conversion kits, directional control conversion kits, mast connection hose kits, miscellaneous and seat conversion kits, header hose conversion kits for A389, A399, A387 and A397 mast series, light kits, quick disconnect kits with E-Hydraulics, carriage gland repair kits
• Section 17 – Numerical Index: full part number index showing page and item reference for every part listed in the book
• Section 18 – User Support Information: service parts ordering instructions, technical service publications, operator training and service training information

What This Parts Manual Gives You

Every one of the eighteen sections is built around a visual breakdown rather than a wall of text. Each assembly page carries a labelled illustration with numbered callouts, and directly beneath it a parts table listing the item number, part number, description and the quantity needed. Sub-parts are indented under the assemblies they belong to, so you can see at a glance whether a bearing cap, seal or spring is a separate orderable item or part of a larger assembly. Keys marked A, B, C, D and E separate right-hand from left-hand assemblies and the different build variants, and the quantity columns are divided accordingly, so a truck with foot directional control and a truck with a forward/reverse lever do not send you to the wrong page.

The manual also handles the fact that these trucks changed over their production life. Serial number breaks are used throughout to mark the last unit affected by an older part and the first unit affected by the newer one, and date breaks are used where a change happened but no serial break was recorded. Pending changes are flagged with ECN numbers, which tells you the part listed is tied to an engineering change that had not yet reached a specific serial number at the time of publication. Part numbers with a supersession history appear in the order they were superseded, with the old numbers struck through so you can trace what a discontinued number was replaced by. Where a part is not serviced separately, the part number column carries periods instead of a number, and a pointing-hand reference sends you to the correct parts page for the sub-component. That level of bookkeeping is what keeps a parts order from coming back wrong.

Identification is covered properly as well. The opening pages explain the model nomenclature code position by position, so the string on the nameplate tells you the power type, tire type, rated capacity, special designation, hazardous location rating, lowered mast height, mast type, transmission type, engine model, manufacturing source and design series. Later pages show exactly where the truck serial number is stamped on the frame and printed on the nameplate, how to read a mast identification number and carriage travel in millimetres, where the fork part number and capacity rating are stamped on the fork blade, and where the carriage group number and date code sit on pin-type and hook-type carriages. For side-shift carriages and attachments, the manual shows the nameplate location so you can pull the attachment serial number. Getting these numbers right before you order is the difference between a correct shipment and a return.

The parts coverage itself reaches into genuinely detailed territory. On the engine side you get the PSI 2.4L LPG and Bi-Fuel assemblies broken down to cylinder head, camshaft and valves, rocker cover, piston and crankshaft, front cover and oil pan, oil pump, water pump, thermostat and DRS circuit, and on the Yanmar side the 2.6L and 3.3L diesel assemblies down to cylinder block, cylinder head, crankshaft and pistons, lubrication system, injection pump, fuel injection system, gear housing and a full engine gasket kit. The transmission section covers the housing, input/forward clutch, counter/reverse clutch, torque converter housing, and the inching valve down to individual springs, spools, pistons and seals. Brake coverage includes both the GP040-GP050MX and GP060MX brake assemblies with wheel cylinder repair kits, brake shoe kits, adjuster kits, cables, park brake assemblies and the master cylinder. Hydraulics run from the gear pump and pump drive through the manual and electro-hydraulic control valve sections to the tilt cylinders and accumulator, with hand lever assemblies including detent and RTST versions. Mast coverage is split by mast series and by build date, and the options section covers everything from integral side-shift carriages and fork positioners to telemetry and speed limiters.

Who This Manual Is For

This is a working reference for the person who has to put a part number on a requisition and get it right the first time. Fleet maintenance shops running GP and GLP series trucks, independent forklift service companies, and parts counter staff will all get use out of it. It is equally useful for an owner-operator who wants to see how an assembly is put together before pulling it apart, or who needs to confirm whether a seal comes with a cylinder kit or has to be ordered on its own. Because the book splits coverage by engine, by mast series and by build date, it also works as a way to check what actually applies to a specific truck rather than assuming every GP040MX on the yard takes the same parts.

Order the Right Part the First Time

Ordering a replacement part for a lift truck without the illustrated breakdown means working from a description, a guess or a phone call to someone who may not know either. With this Yale GP040MX GP050MX GP060MX parts manual open, you can trace an assembly down to the exact detail part, confirm the quantity, check whether a serial number or date break applies to your truck, and see whether the number you have in hand has been superseded. That is the difference between a truck back in service the same day and a truck sitting idle waiting on a second shipment.

Because the manual covers the GP040MX, GP050MX and GP060MX along with the GLP LP-gas variants and the Yanmar diesel engines, a shop with a mixed fleet gets one reference instead of several. Whether you are rebuilding a brake assembly, resealing a tilt cylinder, replacing a chain sheave, sourcing a carriage load roller, tracking down an electrical connector in the frame harness, or simply confirming the correct fork for a Class II or Class III carriage, the information is in here.

IMAGES PREVIEW

The file is delivered as an instant PDF download after payment. There is nothing to wait for in the post and nothing to pay in shipping. It opens on a laptop, desktop, tablet or phone, the pages can be zoomed in on the exploded views, and any page or parts list you use often can be printed and kept at the bench or in the service truck. For anyone maintaining Yale GP040MX, GP050MX or GP060MX lift trucks, this parts manual is the reference that keeps the parts orders accurate.