Jungheinrich EKS 110 Service Manual 2015 – Complete Repair & Maintenance Guide

Description

Jungheinrich EKS 110 Service Manual 2015

The Jungheinrich EKS 110 Service Manual 2015 is the full workshop documentation for the EKS 110 series of electric narrow-aisle order pickers. At 557 pages, this is not a condensed owner’s booklet — it is the complete technical reference used for scheduled maintenance, fault diagnosis, component replacement, and electrical/hydraulic troubleshooting across all EKS 110 variants, including the 100E, 160E, 190E, and 280ZZ models. Whether you are servicing a drive brake, tracing a CAN-Bus fault, adjusting the auxiliary lift, or interpreting an event message from the master logbook, this Jungheinrich EKS 110 repair manual provides the procedures and specifications required.

File Details

• Manual Type: Full workshop service manual
• Brand: Jungheinrich
• Model: EKS 110
• Covered Variants: EKS 110 100E, 160E, 190E, 280ZZ (L and Z versions)
• Language: English
• Page Count: 557 pages
• File Format: PDF
• Publication Date: 2015 (dated 04.15 and 03.15 in various sections)
• Document Number: 300119825_000_05 (circuit diagrams)

Chapters Covered

• Brakes — Spring-loaded drive brake, minimum braking distance measurement, air gap checks, brake replacement
• Steering — AS 2412 iS dual controller, RSC28 MH angle sensor, group rotary angle sensor, electric steering adjustment and teach-in
• Controls & Access — Access components (Easy Access), deadman switch, ISM access module, key switch and transponder functions
• Electrical System — AS 2412 iS dual controller, MFC10 multifunction controller, EKS 110 plugs and connectors, fuses, wiring diagrams
• Hydraulic System — Bleeding hydraulic cylinders, oil level checking, line-rupture safety valves, proportional valve adjustment, hydraulic circuit diagrams
• Battery — Maintenance, recharging, replacement, battery management system, electrolyte level sensors
• Drive & Transmission — Drive motor, transmission, protective cap replacement, debris guard and seal, drive wheel removal and installation
• Wheels & Rollers — Drive wheel, load wheel, guide rollers, wear limits, shim adjustment
• Mast & Load Handling — Mast rollers, load chains (cleaning, inspection, lubrication, wear limits), fork carriage adjustment, auxiliary lift magnetic switch
• Maintenance & Inspection — Maintenance checklists B and C (standard and cold-store), regular safety inspection intervals, lubrication schedule
• Commissioning — Transport and commissioning, initial setup procedures
• Technical Specifications — Drive system, transmission, wheels, steering, hydraulic system, pump motor, pressures, torques
• Event Messages & Diagnostics — Full FEXX event code tables with operational status, description, cause, and corrective action
• Circuit Diagrams — Electrical (EKS 110, CANopen) and hydraulic (E, ZZ, ZG variants)
• ISM Online — Access module, data recorder, radio module, retrofitting, parameter setting, CAN-Bus versions, gateway configuration
• Tightening Torques — Component-specific torque values for lift mast, transmission, drive motor, valve block, steering head, drivetrain, lift cylinder, load handler, electrical system
• Parameters — Travel programs, steering parameters, battery parameters, global parameters with ranges and default settings
• Pin Assignments — Connector pinouts for travel switch, valves, controllers, ISM components, sensors, and lighting

The manual is structured for practical workshop use: each system is treated with component layout diagrams, exploded views, step-by-step removal and installation procedures, adjustment dimensions with tolerance values, and where applicable, teach-in or calibration routines via the Jungheinrich JUDIT service tool. The event message tables alone span more than 120 pages and provide the exact trigger conditions, operational status, and corrective actions for every logged fault — from drive motor phase faults and CAN-Bus communication errors to brake force governor teach-in issues and ISM access module parameter errors. The electrical and hydraulic circuit diagrams are broken down by function group and include connector references that map directly to the pin assignment tables.

What This Manual Enables You to Do

With the Jungheinrich EKS 110 service manual 2015 on hand, you can perform the full range of maintenance and repair tasks that keep an EKS 110 order picker operating safely and efficiently. This includes:

• Diagnose faults using the FEXX event message code system and trace them to the exact component or circuit
• Adjust and replace the spring-loaded drive brake and verify braking distance to specification
• Teach in steering angle sensors and set steering parameters correctly via JUDIT
• Replace drive wheels, load wheels, and guide rollers with correct torque sequences and shim arrangements
• Check and top up hydraulic oil for main lift (100E, 160E, 190E, 280ZZ) and auxiliary lift circuits
• Bleed hydraulic cylinders on single-stage and two-stage telescopic masts
• Test line-rupture safety valves on both E and ZZ masts with the prescribed test load
• Inspect, clean, lubricate, and measure load chains for elongation and link plate wear
• Adjust the auxiliary lift fork carriage and magnetic switches to exact dimensions
• Set travel program parameters, speed limits, acceleration curves, and brake ramps
• Replace and configure ISM Online components including access module, data recorder, and radio module
• Interpret CAN-Bus node IDs and troubleshoot communication faults
• Carry out scheduled maintenance per checklist B and C, including cold-store variants
• Apply correct tightening torques to every bolted connection on the truck
• Read and use the electrical and hydraulic circuit diagrams for fault tracing

Why This Manual Matters

The EKS 110 is a complex piece of material handling equipment with electronic steering, CAN-Bus communication, regenerative braking, and hydraulic load handling systems. Working without the correct specifications — whether it is a torque value, an air gap, a pressure setting, or a teach-in procedure — risks damage to components, unsafe operation, and costly repeat repairs. This manual gives you the exact figures and procedures that Jungheinrich specifies, including the tolerance ranges and activation limits that determine whether a component is within service limits or requires replacement.

The event message diagnostic section is particularly valuable: rather than guessing why a fault code appeared, you can look up the exact trigger condition, the operational status when it occurred, and the recommended action — whether that is checking a wire connection, replacing a sensor, re-teaching a function via JUDIT, or replacing a controller. For workshops that service multiple EKS 110 variants, the manual covers the differences between the 100E, 160E, 190E, and 280ZZ models throughout, so you are not working from generic instructions that do not match the truck in front of you.

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Instant PDF Delivery

The Jungheinrich EKS 110 repair manual is delivered as a PDF download immediately after purchase. There is no shipping, no waiting for a physical book, and no restrictions on how many times you access it. You can view it on a laptop, tablet, or smartphone in the workshop, print the pages you need for a specific job, or keep the full 557-page document on a service computer for reference. Every diagram, table, and procedure is exactly as Jungheinrich published it — giving you the complete workshop reference for the EKS 110 in one searchable file.