This document provides descriptions and service procedures for parts of the frame on a lift truck model ERP20-32ALF (ERP040-065DH) (E216). It describes the main components of the frame including the main frame, overhead guard, hood and seat assembly, and counterweight. It provides instructions for replacing components like the overhead guard, hood and seat assembly, and counterweight. It also describes the battery restraint system and provides specifications for the batteries that can be used.

1. ERP20-30ALF (E216)
SERVICE MANUAL CONTENTS
SECTION
PART
NUMBER
YRM
NUMBER
REV
DATE
FRAME............................................................................................................................ 524256685 0100 YRM 1222 05/06
DC MOTOR MAINTENANCE.......................................................................................... 524158039 0620 YRM 0294 03/08
AC MOTOR MAINTENANCE.......................................................................................... 524183080 0620 YRM 1053 03/10
DRIVE AXLE WET BRAKE............................................................................................ 524256686 1400 YRM 1223 03/09
STEERING CONTROL UNIT.......................................................................................... 524158753 1600 YRM 0720 11/06
STEERING SYSTEM...................................................................................................... 524183081 1600 YRM 1054 11/06
BRAKE PEDAL AND LINKAGE..................................................................................... 524264587 1800 YRM 1253 09/06
HYDRAULIC SYSTEM.................................................................................................... 524179945 1900 YRM 0559 04/09
MAIN CONTROL VALVE................................................................................................ 524179946 2000 YRM 0562 02/09
MAIN CONTROL VALVE E-CONTROLS....................................................................... 524256687 2000 YRM 1224 04/08
CYLINDER REPAIR (MAST S/N A551, A555, A559, A661, A662, A663, A66, B507,
B508, B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515,
C551, C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND
E564).......................................................................................................................... 524223768 2100 YRM 1139 02/14
ELECTRICAL SYSTEM.................................................................................................. 524183082 2200 YRM 1055 10/09
AC MOTOR CONTROLLER DESC/CHKS/ADJ/TRBSHT/REP&THEORY OF
OPERATION/DISPLAY PANEL................................................................................. 524183083 2200 YRM 1056 03/09
TROUBLESHOOTING AND ADJUSTMENTS USING THE AC CONTROLS
PROGRAM................................................................................................................. 524183085 2200 YRM 1058 04/11
INDUSTRIAL BATTERY................................................................................................. 524158040 2240 YRM 0001 09/14
MAST - DESCRIPTION................................................................................................... 524158890 4000 YRM 0521 03/06
MAST REPAIRS (S/N A551, A555, A559, A661, A662, A663, A664, B507, B508,
B509, B551, B555, B559, B562, B563, B564, B661, B662, B663, C515, C551,
C555, C559, D507, D508, D509, D515, D562, D563, D564, E509, AND E564)........ 524223776 4000 YRM 1148 02/14
METRIC AND INCH (SAE) FASTENERS....................................................................... 524150797 8000 YRM 0231 10/13
DIAGRAMS..................................................................................................................... 524256688 8000 YRM 1225 05/06
PERIODIC MAINTENANCE............................................................................................ 524309198 8000 YRM 1226 08/08
CAPACITIES AND SPECIFICATIONS........................................................................... 524256690 8000 YRM 1227 05/06
PART NO. 524309197 (09/14)

2. SAFETY PRECAUTIONS
MAINTENANCE AND REPAIR
• When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fas-
tened, and that the load being lifted is balanced. Make sure the crane, cables, and chains
have the capacity to support the weight of the load.
• Do not lift heavy parts by hand, use a lifting mechanism.
• Wear safety glasses.
• DISCONNECT THE BATTERY CONNECTOR before doing any maintenance or repair on
electric lift trucks. Disconnect the battery ground cable on internal combustion lift trucks.
• Always use correct blocks to prevent the unit from rolling or falling. See HOW TO PUT THE
LIFT TRUCK ON BLOCKS in the Operating Manual or the Periodic Maintenance section.
• Keep the unit clean and the working area clean and orderly.
• Use the correct tools for the job.
• Keep the tools clean and in good condition.
• Always use YALE APPROVED parts when making repairs. Replacement parts must meet
or exceed the specifications of the original equipment manufacturer.
• Make sure all nuts, bolts, snap rings, and other fastening devices are removed before using
force to remove parts.
• Always fasten a DO NOT OPERATE tag to the controls of the unit when making repairs, or
if the unit needs repairs.
• Be sure to follow the WARNING and CAUTION notes in the instructions.
• Gasoline, Liquid Petroleum Gas (LPG), Compressed Natural Gas (CNG), and Diesel fuel are
flammable. Be sure to follow the necessary safety precautions when handling these fuels
and when working on these fuel systems.
• Batteries generate flammable gas when they are being charged. Keep fire and sparks away
from the area. Make sure the area is well ventilated.
NOTE: The following symbols and words indicate safety information in this manual:
WARNING
Indicates a condition that can cause immediate death or injury!
CAUTION
Indicates a condition that can cause property damage!

3. Frame Table of Contents
TABLE OF CONTENTS
General................................................................................................................................................................ 1
Description .......................................................................................................................................................... 1
Main Frame ..................................................................................................................................................... 1
Other Frame Weldments ................................................................................................................................. 1
Overhead Guard ............................................................................................................................................. 1
Battery Restraint, Hood, and Seat Assembly.................................................................................................. 5
Hood With Manual Hydraulic Levers ............................................................................................................... 6
Hood With E-Hydraulics .................................................................................................................................. 7
Operator Restraint System and Seat Assembly.............................................................................................. 8
Operator Restraint System ......................................................................................................................... 8
Emergency Locking Retractor (ELR)...................................................................................................... 8
Hood and Seat Latches .............................................................................................................................. 9
Overhead Guard Replacement............................................................................................................................ 9
Remove........................................................................................................................................................... 9
Install............................................................................................................................................................... 9
Hood, Seat Assembly, and Operator Restraint Replacement.............................................................................. 11
Hood and Seat Assembly................................................................................................................................ 11
Remove....................................................................................................................................................... 11
Install .......................................................................................................................................................... 13
Counterweight Replacement ............................................................................................................................... 17
Remove........................................................................................................................................................... 17
Install............................................................................................................................................................... 17
Hydraulic Tank Replacement............................................................................................................................... 18
Remove........................................................................................................................................................... 18
Inspect............................................................................................................................................................. 18
Clean............................................................................................................................................................... 19
Steam Method ............................................................................................................................................ 19
Chemical Solution Method.......................................................................................................................... 19
Additional Preparations for Tank Repair.......................................................................................................... 20
Small Leaks, Repair........................................................................................................................................ 20
Large Leaks, Repair........................................................................................................................................ 20
Preparations for Usage After Repair ............................................................................................................... 20
Install............................................................................................................................................................... 20
Painting Instructions ............................................................................................................................................ 21
Safety Label Replacement .................................................................................................................................. 23
Battery Specifications.......................................................................................................................................... 25
ERP20-32ALF (ERP040-065DH) (E216) Model Trucks.................................................................................. 25
This section is for the following models:
ERP20-32ALF (ERP040-065DH) [E216]
©2006 Yale Materials Handling Corp. i

4. 100 YRM 1222 Description
General
This section has a description and the service procedures for the parts of the frame. These parts include the frame,
counterweight assembly, overhead guard, hood and seat assembly, access panels, and label positions.
Description
MAIN FRAME
The main frame is a single weldment. See Figure 1.
The main frame has mounts for the following:
• Counterweight
• Overhead guard
• Battery restraint and hood
• Tilt cylinders
• Steering axle
• Drive axle assembly
• Cowl assembly
• Floor pedals and floor plates
• Side step and fender weldments
• Hydraulic tank
• Pump and motor assemblies (steer, lift, and traction
motors)
• Control valves and the levers
The hood is part of the operator and battery restraint
system. The seat is part of the operator restraint sys-
tem. The hydraulic tank, lift pump motor assembly, and
the steering pump motor assembly are in a compart-
ment between the battery and the counterweight. The
top cover between the counterweight and hood can be
removed for access to the master controller. The rear
cover of the counterweight can be removed for access
to the controllers and contactors. See Figure 2.
The weight of the battery is a large part of the counter-
weight system on an electric lift truck. Make sure that
the battery is within the weight limits indicated on the
nameplate. Each model of lift truck has a cast iron coun-
terweight that provides additional weight necessary for
the indicated capacity.
OTHER FRAME WELDMENTS
These frame parts are the right-side and left-side step
and fender weldments and the cowl weldment. See Fig-
ure 1. Each part is a weldment fastened to the main
frame to make the frame assembly. The cowl weldment
is a mount for the front of the overhead guard, the steer-
ing column assembly, the parking brake release link-
age, and the dash panel with light switches. The display
panel is mounted into the dash panel. See Figure 3.
OVERHEAD GUARD
WARNING
Do not operate the lift truck without the overhead
guard and cowl correctly fastened to the lift truck.
The overhead guard is a weldment that fastens to the
main frame and cowl to help protect the operator from
falling objects. A slot in the overhead guard permits
removal of the battery without removing the overhead
guard. See Figure 2.
1

5. Description 100 YRM 1222
1. COWL
2. BATTERY SPACER PLATE
3. BATTERY RETAINER ROD
4. FRAME
5. SIDE STEP AND FENDER WELDMENT
6. ACCESS PANEL
7. FLOOR PLATES
Figure 1. Lift Truck Main Frame
2

6. 100 YRM 1222 Description
1. OVERHEAD GUARD
2. HANDLE
3. ROLLING THREAD SCREW
4. NUT
5. WASHER
6. CAPSCREW
7. TOP COVER
8. TOW PIN
9. FOAM TAPE
10. REAR COVER
11. SOCKET CAPSCREW
12. LOCKWASHER
13. COUNTERWEIGHT
14. SEAL
15. SPACER
16. BRACKET
17. SELF RETAINING NUT
18. HOLE PLUG
Figure 2. Overhead Guard and Counterweight
3

7. Description 100 YRM 1222
Figure 3. Steering Column and Display Panel
4

8. 100 YRM 1222 Description
Legend for Figure 3
1. ON-DEMAND STEERING COMPONENTS
2. SHIFT LEVER MECHANISM
3. STEERING WHEEL
4. DISPLAY PANEL
5. COLUMN COVER
6. COLUMN FRAME
7. STEERING CONTROL UNIT
8. COWL WELDMENT
9. DASH PANEL
10. COLUMN MOUNT
11. LATCH MECHANISM
12. HORN SWITCH CONNECTOR
13. HORN BUTTON
14. STEERING COLUMN
15. STEERING COLUMN NUT
16. STATIC STRAP
BATTERY RESTRAINT, HOOD, AND SEAT
ASSEMBLY
WARNING
The hood and battery restraint, as well as the latch
for the hand lever assembly, must operate correctly
before a lift truck is operated. These parts are part
of the battery restraint system. The battery restraint
system must operate correctly to help provide rea-
sonable protection to the operator if the lift truck
tips over.
A battery restraint system is installed as a safety de-
vice. The function on the battery restraint system is to
hold the battery in the battery compartment in case of a
tip over. Part of the battery restraint system is a battery
restraint at the rear of the battery compartment. See
Figure 4. This restraint rod extends over the rear edge
of the battery case to help hold the battery within the
battery compartment during tip over. A handle is used
to move the restraint rod. The handle of the battery re-
straint must be in the DOWN position to close the hood.
The handle can be moved to the DOWN position only
after the restraint rod is extended over the battery. The
restraint rod can only be retracted when the hood is in
the UP position.
WARNING
The battery must fit the battery compartment so
that the battery restraint will operate correctly. A
loose battery can cause serious injury and property
damage if the lift truck overturns. The battery must
not be able to move more than 13 mm (0.5 in.) for-
ward, backward, or side to side.
An adjustable spacer plate is used at the front of the
battery compartment to prevent forward and backward
movement of the battery. The adjustable spacer plate is
used inside the battery compartment. The spacer plate
must be adjusted for a maximum clearance of 13 mm
(0.5 in.) with the battery against the rear bulkhead. See
Figure 5. There must be some clearance to allow bat-
tery removal. See the section Periodic Maintenance
8000 YRM 1226 to remove the battery and adjust the
spacer plate.
A. EXTENDED
B. RETRACTED
1. BATTERY RESTRAINT WARNING LABEL
2. HOOD
3. BATTERY RESTRAINT HANDLE
4. BATTERY
Figure 4. Battery Restraint Rod
5

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10. Description 100 YRM 1222
1. BATTERY COMPARTMENT
2. BATTERY
3. BULKHEAD
4. SPACER PLATE
5. ADJUSTMENT CAPSCREW
6. JAM NUT
Figure 5. Battery Spacer Plate
HOOD WITH MANUAL HYDRAULIC
LEVERS
WARNING
The gas spring for the hood can raise the hood at
a rapid rate and cause an injury. DO NOT lean over
hood when raising hood.
WARNING
The batteries for these lift trucks must fit the battery
compartment width with a maximum of 13 mm (0.5
in.) clearance. The Battery Specifications, at the
back of this manual, shows the minimum sizes of
the battery compartment.
Before raising the hood, move the steering column to
the forward position and slide the seat all the way back.
Another important part of the battery restraint system
is the steel weldment that is also the hood frame. This
hood frame is connected to the lift truck frame with
hinges at the rear of the hood. See Figure 15. The
front of the hood and frame is locked in the closed po-
sition by the assembly for the hydraulic hand levers. A
latch releases the assembly to tilt forward and allow the
hood to raise. See Figure 6. Gas springs help lift the
hood assembly. The seat and other parts of the opera-
tor restraint system fasten to the hood assembly.
A. CLOSED OVER HOOD B. OPEN
1. HAND LEVER ASSEMBLY
2. HOOD
3. SEAT
4. LATCH HANDLE
5. LATCH
Figure 6. Latch and Cover With Manual Hydraulic Levers
6

11. 100 YRM 1222 Description
HOOD WITH E-HYDRAULICS
WARNING
The gas spring for the hood can raise the hood at
a rapid rate and cause an injury. DO NOT lean over
hood when raising hood.
WARNING
The batteries for these lift trucks must fit the battery
compartment width with a maximum of 13 mm (0.5
in.) clearance. The Battery Specifications, at the
back of this manual, shows the minimum sizes of
the battery compartment.
Another important part of the battery restraint system
is the steel weldment that is also the hood frame. This
hood frame is connected to the lift truck frame with
hinges at the rear of the hood. See Figure 14. Gas
springs help lift the hood assembly. The seat and other
parts of the operator restraint system fasten to the hood
assembly.
NOTE: Before raising the hood, move the steering col-
umn to the forward position and slide the seat all the
way back, and, If necessary, move the armrest all the
way back. See Figure 7.
1. ARMREST ADJUSTMENT HANDLE
Figure 7. Armrest Latch Location
The latch that secures the cover for the hood release
handle can be either a locking or non-locking latch. If
the latch is a locking latch, unlock latch with key first.
The cover, latch, and hood release handle are located
on the right side of the hood. See Figure 8.
Pull the latch handle, located on the top of the latch, to
the up position and then pull on latch handle to move
cover away from hood release handle. Pull hood re-
lease handle up to release hood latch mechanism. See
Figure 8. Use handle on the hood to place hood in the
raised position.
Before lowering the hood, make sure the battery re-
straint rod is over the battery. Lower the hood and push
hood release handle down to secure hood to frame.
Move cover over hood release handle and push latch
handle down to secure cover to hood. If latch is a lock-
ing latch, lock latch with key.
1. LATCH
2. COVER
3. HOOD RELEASE
HANDLE
4. HOOD LATCH
MECHANISM
5. COMPRESSION
SPRING
6. PIN
7. SCREW
8. CAPSCREW
9. NUT
10. LOCKWASHER
11. WASHER
12. LATCH HANDLE
Figure 8. Latch and Cover With E-Hydraulics
7

12. Description 100 YRM 1222
OPERATOR RESTRAINT SYSTEM AND
SEAT ASSEMBLY
Operator Restraint System
The seat belt, hip restraint, seat, hood, and hood latch
are all part of the operator restraint system. See Fig-
ure 9. Each item must be checked to make sure it is
fastened correctly, functions correctly, and is in good
condition. The system helps the operator stay within
the lift truck in case of a tip over.
Make sure that the seat is not loose on the rails. Make
sure that the seat rails are not loose. The seat rails
must lock securely in position, but move freely when
unlocked. The seat rails must be securely attached to
the mounting surface.
Emergency Locking Retractor (ELR)
When the ELR style seat belt is properly buckled across
the operator, the belt will permit slight operator reposi-
tioning without activating the locking mechanism. If the
truck tips, travels off a dock, or comes to a sudden stop,
the locking mechanism will be activated and hold the
operator’s lower torso in the seat.
A seat belt that is damaged worn or does not operate
properly will not give protection when it is needed. The
end of the belt must fasten correctly in the latch. The
seat belt must be in good condition. Replace the seat
belt if damage or wear is seen. See Figure 9.
The following seat belt operation checks must be per-
formed:
• With the hood closed and in the locked position, pull
the seat belt slowly from the retractor assembly. Make
sure the seat belt pulls out and retracts smoothly. If
the seat belt cannot be pulled from the retractor as-
sembly or the belt will not retract, replace the seat belt
assembly.
• With the hood closed and in the locked position, pull
the seat belt with a sudden jerk. Make sure the seat
belt will not pull from the retractor assembly. If the
seat belt can be pulled from the retractor, when it is
pulled with a sudden jerk, replace the seat belt as-
sembly.
• With the hood in the open position, make sure the
seat belt will not pull from the retractor assembly. If
the seat belt can be pulled from the retractor, with
the hood in the open position, replace the seat belt
assembly.
1. OPERATOR WEIGHT ADJUSTMENT
2. FORWARD BACKWARD ADJUSTMENT
3. SEAT BELT
4. HIP RESTRAINT
5. SEAT
6. SEAT RAIL
Figure 9. Hood and Seat Check
1. FORWARD/BACKWARD ADJUSTMENT
2. SWIVEL ADJUSTMENT
3. OPERATOR WEIGHT ADJUSTMENT
4. SEAT POSITION ADJUSTMENT (SEAT RAIL)
5. SEAT BELT
Figure 10. Swivel Seat Option
8

13. 100 YRM 1222 Overhead Guard Replacement
Hood and Seat Latches
Make sure the seat rails and latch striker are not loose.
The seat rails must lock tightly in position, but move
freely when unlocked (see Figure 9 and Figure 10). The
seat rails must be correctly fastened to the hood and the
fastened to the hinges on the frame. Try to lift the hood
to make sure it is fastened correctly and will not move.
Overhead Guard Replacement
REMOVE
WARNING
Do not weld, drill, grind, or cut the overhead guard
for mounts of lights or accessories. The strength
of the overhead guard can be reduced.
1. Remove battery as described in the section Peri-
odic Maintenance 8000 YRM 1226.
2. Access to the capscrews that hold the rear legs of
the overhead guard to the frame is from the battery
compartment. See Figure 11. Remove the cap-
screws, washers, and nuts that fasten each leg.
3. Remove the capscrews, washers, and nuts that
hold each front leg of the overhead guard to the
cowl. Disconnect any electric wires from under the
cowl that go through the front legs of the overhead
guard. When the overhead guard is lifted from the
frame, make sure these electric wires move through
the holes in the frame at the front and rear so that
they are not damaged.
4. Use a lifting device or another person to help lift the
overhead guard from the lift truck.
INSTALL
1. Install the over head guard onto the lift using a lifting
device or another person.
2. Install any electrical wires from the overhead guard
legs through the holes in the frame. Make sure
location of the wires is routed in the same location
as was removed to assure that the wires do not get
pinched.
3. Install the capscrews, washers, and nuts that hold
each front leg to the frame. See Figure 11. Tighten
the capscrews to 102 N•m (75 lbf ft).
4. Install the caspcrews, washers, and nuts that hold
the rear legs to the frame. See Figure 11. Tighten
the capscrews to 102 N•m (75 lbf ft).
5. Install the battery as described in the section Pe-
riodic Maintenance 8000 YRM 1226.
9