Service Manual
JS1-H Serviceability
IP54 Joysticks
www.danfoss.com
Service Manual
JS1-H Serviceability for IP54 Joysticks
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
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Service Manual
JS1-H Serviceability for IP54 Joysticks
Contents
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
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JS1-H Serviceability for IP54 Joysticks
HR1, ST7, PR2, ST2, PR7
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.
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HR1, ST7, PR2, ST2, PR7
3. Remove the 4 screws to open the cup.
4. Unplug the cable connector.
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JS1-H Serviceability for IP54 Joysticks
HR1, ST7, PR2, ST2, PR7
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.
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HR1, ST7, PR2, ST2, PR7
Grip removal from base
Loosen the 2 set screws and carefully remove the grip (not HR1 and PR7).
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HR1, ST7, PR2, ST2, PR7
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.
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HR1, ST7, PR2, ST2, PR7
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.
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ST7, PR2, ST2
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.
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ST7, PR2, ST2
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.
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JS1-H Serviceability for IP54 Joysticks
ST7, PR2, ST2
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
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ST7, PR2, ST2
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
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ST7, PR2, ST2
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
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ST7, PR2, ST2
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.
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ST7, PR2, ST2
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.
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HR1
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.
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.
Use: Allen Key 2.5 mm, Torque: 2.8 Nm
To tighten the grip back on, use the tool and torque noted.
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.
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JS1-H Serviceability for IP54 Joysticks
HR1
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.
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JS1-H Serviceability for IP54 Joysticks
HR1
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.
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JS1-H Serviceability for IP54 Joysticks
PR7
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.
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PR7
2. The grip will be divided in 3 parts. It is possible to remove the desired item to replace by using the
fingers to push it out.
3. Close the grip and tighten the screws again.
Use: T10, Torque: 1.3 Nm
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PR7
Grip replacement
4. Follow steps under PCBA, cup and cable assembly on page 13 to reassemble the whole joystick.
Process as described for the push button with the addition of the removal of the grip. In order to change
the grip, remove all the items, refer to Items and grip disassembly on page 20 step 2, then separate the
grip from the base.
1. Loosen the setscrew to remove the grip from the base and replace it.
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JS1-H Serviceability for IP54 Joysticks
PR7
2. Tighten the setscrew again, refer to Grip replacement on page 22, step 3 to reassemble.
Use: T10, Torque: 2.8 Nm
Boot replacement
The grip will need to be removed as described under Grip removal from base on page 7. After removing
the grip, it is possible to follow the steps under Boot replacement on page 8 to replace the boot if desired.
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Danfoss
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