Danfoss JS1-H Serviceability User manual

Service Manual
JS1-H Serviceability
IP54 Joysticks
www.danfoss.com

Revision history Table of revisions
Date Changed Rev
July 2019 Literature type corrected back to Service Manual and correct literature id number 0103
July 2019 Title corrected and Literature id number changed 0102
July 2019 First edition 0101
Service Manual
JS1-H Serviceability for IP54 Joysticks
2 | ©Danfoss | July 2019 AX311058842185en-000103

HR1, ST7, PR2, ST2, PR7 Cup and cable disassembly.......................................................................................................................................................... 4
PCBA removal.................................................................................................................................................................................... 6
Grip removal from base..................................................................................................................................................................7
Boot replacement.............................................................................................................................................................................8
Cable and cup replacement......................................................................................................................................................... 9
ST7, PR2, ST2 Items and faceplate removal..................................................................................................................................................... 10
Items and faceplate assembly...................................................................................................................................................12
Grip assembly..................................................................................................................................................................................13
PCBA, cup and cable assembly................................................................................................................................................. 13
Grip replacement........................................................................................................................................................................... 16
HR1 Grip removal from base...............................................................................................................................................................17
Boot, cup and cable replacement............................................................................................................................................17
Items and grip disassembly........................................................................................................................................................18
Items and grip reassembly..........................................................................................................................................................19
PR7 Cup and cable replacement.......................................................................................................................................................20
Items and grip disassembly........................................................................................................................................................20
Items replacement.........................................................................................................................................................................20
Grip replacement........................................................................................................................................................................... 22
Boot replacement.......................................................................................................................................................................... 23
Service Manual
JS1-H Serviceability for IP54 Joysticks
Contents
©Danfoss | July 2019 AX311058842185en-000103 | 3

In order to remove the desired item/ items, the following first steps need to be followed no matter what
grip is being used.
Cup and cable disassembly
1. Remove the retainer by carefully opening the snap with a screwdriver.
The snap can be easily broken. If it is broken, a new cable will need to be purchased.
2. Carefully pull back the grommet while holding the cable.
Service Manual
JS1-H Serviceability for IP54 Joysticks
HR1, ST7, PR2, ST2, PR7
4 | ©Danfoss | July 2019 AX311058842185en-000103

3. Remove the 4 screws to open the cup.
4. Unplug the cable connector.
Service Manual
JS1-H Serviceability for IP54 Joysticks
HR1, ST7, PR2, ST2, PR7
©Danfoss | July 2019 AX311058842185en-000103 | 5

PCBA removal
1. Take a picture to ease the re-installing of the connectors. Unplug all PCBA connectors.
2. Remove the 3 screws from the bottom plate and remove the PCBA.
Service Manual
JS1-H Serviceability for IP54 Joysticks
HR1, ST7, PR2, ST2, PR7
6 | ©Danfoss | July 2019 AX311058842185en-000103

Grip removal from base
Loosen the 2 set screws and carefully remove the grip (not HR1 and PR7).
Service Manual
JS1-H Serviceability for IP54 Joysticks
HR1, ST7, PR2, ST2, PR7
©Danfoss | July 2019 AX311058842185en-000103 | 7

Boot replacement
Grip must be removed, as describe in Grip removal from base on page 7.
The boot can be replaced if desired with the following steps.
1. Hold the boot tightly and pull it off (it is not easy to remove).
2. To re-install the boot, place it all around the base, slightly open it and push down to get in the correct
place.
Service Manual
JS1-H Serviceability for IP54 Joysticks
HR1, ST7, PR2, ST2, PR7
8 | ©Danfoss | July 2019 AX311058842185en-000103

Cable and cup replacement
The case (cup) will need to be removed to install the cable.
The label from the old case will need to be put back on the new case otherwise all information about the
joystick is lost.
The cable will need to be removed to install the new case.
Refer to Cup and cable disassembly on page 4, at step 4 it is possible to replace either the cable or cup.
1. Carefully take the cable connector out through the grommet hole, replace either the cup or cable and
insert the cable again through the grommet hole.
2. Align the two grooves before tightening the cup back on.
Service Manual
JS1-H Serviceability for IP54 Joysticks
HR1, ST7, PR2, ST2, PR7
©Danfoss | July 2019 AX311058842185en-000103 | 9

Cable and case will need to be removed, and wires unplugged and pulled through. New wires need to be
routed into the base and installed correctly, then case and cable re-installed. Purchase of a new faceplate
is required. Rollers can only be replaced on analog joysticks.
In order to remove a push button, roller or rocker, the whole faceplate needs to be removed and
replaced.
Remove a push button or a rocker with a flat screwdriver.
Items and faceplate removal
1. Insert a flat screwdriver between the faceplate and the roller and lift it.
2. Push the buttons out using the fingers.
Service Manual
JS1-H Serviceability for IP54 Joysticks
ST7, PR2, ST2
10 | ©Danfoss | July 2019 AX311058842185en-000103

3. With all items in the faceplate removed, it is now possible to remove the faceplate. Pull it out using
fingers.
4. To re-route all the cables back down to the PCBA, tweezers can be used.
Extreme care is needed since the plug could be pulled out by accident.
Service Manual
JS1-H Serviceability for IP54 Joysticks
ST7, PR2, ST2
©Danfoss | July 2019 AX311058842185en-000103 | 11

Items and faceplate assembly
1. A new faceplate is pushed into the grip and then the same happens with the new items.
2. The cables are then put through the boot and the setscrews tightened (align the back setscrew with
the groove mentioned in Cable and cup replacement on page 9).
Use: Allen Key 2.5 mm, Torque: 2.1 Nm
Service Manual
JS1-H Serviceability for IP54 Joysticks
ST7, PR2, ST2
12 | ©Danfoss | July 2019 AX311058842185en-000103

Grip assembly
Process as described for the push button in Items and faceplate assembly on page 12, with the addition of
the removal of the grip.
PCBA, cup and cable assembly
1. The PCBA is tightened again.
Use: T20, Torque: 2.5 Nm
PCBA
Service Manual
JS1-H Serviceability for IP54 Joysticks
ST7, PR2, ST2
©Danfoss | July 2019 AX311058842185en-000103 | 13

2. The PCBA connectors are plugged in accordingly and the wires are organized and fastened.
Wires are organized and fastened
Printed circuit board
Plug in connectors accordingly
Position Tape color
H1 Red
H2 Yellow
H3 Blue
H4 Black
H5 White
H6 None
H7 Green
Service Manual
JS1-H Serviceability for IP54 Joysticks
ST7, PR2, ST2
14 | ©Danfoss | July 2019 AX311058842185en-000103

Plug in connectors accordingly (continued)
Position Tape color
H8 Blue/Black
H9 Yellow/Black
H10 Yellow/Red
H11 White/Red
H12 White/Green
Prop 3 N/A
Prop 4 Yellow
Prop 5 Red
3. The cable is connected again.
4. Screw the cup back on (check Cable and cup replacement on page 9, for correct placement).
Use: PZ 2, Torque: 1.55 Nm
Make sure cables will not get caught when screwing back on the cup.
Service Manual
JS1-H Serviceability for IP54 Joysticks
ST7, PR2, ST2
©Danfoss | July 2019 AX311058842185en-000103 | 15

5. Put the grommet back in place and push in the snap.
Grip replacement
If the grip needs to be replaced, this should be done after step 2 under Items and faceplate removal on
page 10, when all items have been removed from the faceplate. Then the items are put on the new grip
and assembled following steps under Items and faceplate assembly on page 12 and PCBA, cup and cable
assembly on page 13.
Service Manual
JS1-H Serviceability for IP54 Joysticks
ST7, PR2, ST2
16 | ©Danfoss | July 2019 AX311058842185en-000103

Grip removal from base
It is possible to remove the HR1 grip from the base, after step 2 under PCBA removal on page 6.
1. Remove the two plastic covers to access the setscrews.
2. Loosen the two setscrews to remove the grip from the base.
Use: Allen Key 2.5 mm, Torque: 2.8 Nm
To tighten the grip back on, use the tool and torque noted.
Boot, cup and cable replacement
The grip will need to be removed as described in Grip removal from base on page 17. After removing the
grip, refer to Boot replacement on page 8 to replace the boot if desired.
The case will need to be removed to install the cable.
The label from the old case will need to be put back on the new case otherwise all information about the
joystick is lost.
The cable will need to be removed to install the new case.
Refer to Cup and cable disassembly on page 4, step 4, in order to replace either the cup or cable.
Service Manual
JS1-H Serviceability for IP54 Joysticks
HR1
©Danfoss | July 2019 AX311058842185en-000103 | 17

Items and grip disassembly
In order to remove a push button, roller, or rocker, the cable and case will need to be removed, wires
unplugged and pulled through.
New wires need to be routed into the base and installed correctly.
Rollers can only be replaced on analog joysticks.
1. Remove all the screws from the grip.
2. The grip will now be divided into 3 parts.
Service Manual
JS1-H Serviceability for IP54 Joysticks
HR1
18 | ©Danfoss | July 2019 AX311058842185en-000103

3. Push out the item/ items that are not desired and replace with new ones.
4. Close the grip again and tighten the screws back on.
Use: T10, Torque: 1.3 Nm
Items and grip reassembly
Process as described for the push button in Items and grip disassembly on page 18, with the addition of
the removal of the grip. If the grip needs replacing, remove all the items following Items and grip
disassembly on page 18, step 3 and then replace the grip. Refer to Grip assembly on page 13 to
reassemble the full joystick.
Service Manual
JS1-H Serviceability for IP54 Joysticks
HR1
©Danfoss | July 2019 AX311058842185en-000103 | 19

Cup and cable replacement
The case (cup) will need to be removed to install the cable.
The label from the old case will need to be put back on the new case otherwise all information about the
joystick is lost.
The cable will need to be removed to install the new case.
Refer to Cup and cable disassembly on page 4, step 4, in order to replace either the cup or cable.
Items and grip disassembly
In order to remove a push button, roller, or rocker, the cable and case will need to be removed, wires
unplugged and pulled through.
Rollers can only be replaced on analog joysticks.
Refer to PCBA removal on page 6, it is necessary to open the PR7 grip in order to replace the desired
items.
Items replacement
After step 2, under PCBA removal on page 6 it is necessary to open the PR7 grip in order to replace the
desired items.
1. Remove all the screws to open the grip.
Service Manual
JS1-H Serviceability for IP54 Joysticks
PR7
20 | ©Danfoss | July 2019 AX311058842185en-000103