Clark put its own name on this 445-page factory service manual PDF for the ESM-II electric lift truck family, covering seven variants from the ESM-II 12 through 25. Nearly a third of the book belongs to electrical controls, where EV-100MK troubleshooting and recommended tests sit beside wiring schematics that trace each circuit from the control handle switches to the drive, pump, and steer motors. Hydraulic schematics back up the lift and steering circuit pressure checks, while your drive axle, brake, steering gear, and upright chain jobs each run from removal to installation. Set plugging distance to roughly 6.7 m (22 ft), then confirm the right drive wheel stops once the steering axle trunnion swings 41.5° off center. A contactor rebuild stalls on one number, and it's 1.6-2.0 N·m. Bookmarks and a text layer handle the screen side, but you can also print a chapter and let it take the grease at the bench.
What's Inside This Manual
| System | Pages | Key Topics |
|---|
| Planned Maintenance | 9-26 | Maintenance Schedules, Planned Maintenance Procedures |
| Safe Maintenance | 27-35 | Safety, Lifting, Jacking, And Blocking |
| Battery | 36-44 | Battery Handling |
| Electrical Control Handle | 45-51 | Control Handle Switches |
| Electrical Motors | 52-92 | General Information, Drive Motors, Hydraulic Pump Motor, Steer Pump Motor |
| Electrical Schematics | 93-102 | Wiring Schematics and Diagrams |
| Electrical Controls | 103-235 | Control Panel, Ev-100MK Troubleshooting, Recommended Tests, Equipment, And Procedures, Drive Axle Cut-Out Switch Check and Adjustment, Forward and Reverse Switches |
| Drive Axle | 236-251 | Drive Axle Maintenance, Drive Axle Removal, Drive Axle Disassembly, Drive Axle Assembly, Drive Axle Installation |
| Wheels and Tires | 252-270 | Cushion Wheels and Tires, Pneumatic Drive Tire and Wheel Maintenance |
| Brake System | 271-284 | Brake System and Bleeding, Brake Adjustment, Brake Slave Cylinder |
| Steering Gear | 285-294 | Steering Gear Description, Steering Gear Troubleshooting, Steering Gear Removal, Steering Gear Disassembly, Steering Gear Assembly, Steering Gear Installation |
| Steering Axle | 295-320 | Steering Axle Repair, Power Steering Pump, Steer Torque Generator |
| Hydraulic Pump, Sump and Filters | 321-331 | Hydraulic Pump, Hydraulic Sump and Filter |
| Hydraulic Control Valves | 332-362 | Main Control Valve, Face Seal Fittings, Hydraulic System Pressure Checks - Lift Circuit, Hydraulic System Pressure Checks - Steering Circuit |
| Hydraulic Supply System | 363-368 | Hydraulic System |
| Cylinders | 369-382 | Tilt Cylinder |
| Selector Solenoid Valve | 383-387 | Selector Solenoid Valve Description, Selector Solenoid Valve Troubleshooting, Selector Solenoid Valve Removal, Selector Solenoid Valve Repair, Selector Solenoid Valve Installation |
| Upright | 388-424 | Chain Inspection, Adjustment, And Replacement |
| Specifications | 425-445 | Esm-II Truck Specifications, Esm-II Truck Data Plate, Lubricants and Shop Supplies |
Quick Reference Specifications
| Specification | Value | Page |
|---|
| All Models |
| Fixed contact set bolt torque | 1.6-2.0 N·m (14-18 lb-in.) | p. 116 |
| Armature and movable contact assembly retaining nut torque | 1.6-2.0 N·m (14-18 lb-in.) | p. 116 |
| BDI Lockout battery state of charge threshold | 10% | p. 197 |
| Pinion gear backlash | 0.102-0.198 mm (0.0040-0.0078 in) | p. 250 |
| Flange cap screws torque | 67 N·m (49.5 lb-ft) | p. 250 |
| Power Steering Time Delay | 24 seconds | p. 429 |
| Drive Motor Mounting Bolt Torque | 70-80 N·m (52-59 lb-ft) | p. 63 |
| Drive Axle Mounting Bolt Torque | 408-469 N·m (301-339 lb-ft) | p. 250 |
| Steering Gear Mounting Capscrew Torque | 34-38 N·m (25-28 lb-ft) | p. 294 |
| Hydraulic Pump Mounting Capscrew Torque | 65-73 N·m (48-54 lb-ft) | p. 327 |
| ESM-II 12-17 |
| Tilt Cylinder Relief Pressure (ESM-II 12-17) | 13,780 kPa (2000 psi) | p. 357 |
| ESM-II 20-25 |
| Tilt Cylinder Relief Pressure (ESM-II 20-25) | 15,857 kPa (2300 psi) | p. 357 |
