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OEM
Controls
3120344
March 1, 2008
REVISION LOG
The OEM Controller converts manual input into proportional electrical output signals for the commanding propor- 1
tional flow control valves. The OEM Controller is a seal unit and can withstand hostile and rugged outdoor
weather conditions. The controller handle/stem enters the housing through a sealed entrance, reducing the possi-
bilities of water entering the housing. C
Adjustment of these controllers is done through trimpots on a circuit board (which may be attached to the control-
H
ler or separately mounted in the platform console box) or through a handheld analyzer which adjusts the person-
ality setting in an external module.
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Drive, Steer, Lift and Swing Controllers (All Controllers except 1600272)
These OEM Controllers incorporate a mechanical safety lock whereby the operator must make an additional
A
motion to unlock the control handle prior to operation.This feature eliminates the possibility of the control being C
accidentially energized while in the neutral position. The control handle is spring loaded, and will automatically
return to neutral-off position should should the operator accidentically lose grip of the handle. This feature gives T
the operator positive control of the machine at all times, requiring the operator to hold the control handle during the
duration of the desired function.
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Speed Controller (1600272 Controller Only)
This OEM Controller features a creep/snail function. I
THEORY OF OPERATION
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PWM Output (Pulse Width Modulation)
Because of the mass of the spool, shifting it a very small distance would be very difficult to do without overshoot-
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ing the mark. This overshoot is called hystersis and makes precise control of the function very difficult. PWM out- C
put provides a pulsed current to the spool which actually vibrates the spool so that it is never at rest and very easy
to shift. As you move the handle/stem, the electronics change the time period the pulse is on within that cycle. As
S
you move the handle away from center, the on time period or width of the cycle pulse will increase and as you you
move the handle back towards the center, the pulse will decrease. The percentage of on time to off time of the
PWM signal is called the Duty Cycle, if it is on for 80% it is called an 80% duty cycle.
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4. IRS (RAMP RATE) ADJUSTMENT 2. Seal each trimpot adjustment screw with a drop of
enamel paint, fingernail polish, Loctite #495 Super
a. Turning the "Ramp Rate" trimpot CW increases Bonder or equivalent (do not use super glue) to
S the time it takes to turn ON or OFF when the
handle is moved; CCW decreases the time.
prevent maladjustment due to vibration (See Figure
E b. Trimpot has wide adjustment range, therefore it
2-3 Item 1)
J
U
S 2.2 1600273 ADJUSTMENT
T 1600274 ADJUSTMENT
1600317 ADJUSTMENT
M 1600318 ADJUSTMENT
E NOTE: Refer to Service and Maintenance Manual of the
N specific model machine to be serviced for the cor-
rect calibrations required.
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2.3 CONTROLLER SEALING INSTRUCTION.
c. Further cam rotation shall cause the red switch switch lever near the roller with small pliers (See Fig-
actuator to recede further into switch housing ure 2-6).
after the click is heard.
d. Upon returning joystick to neutral, the switch
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shall release (click is heard) not earlier that 75%
rise of the ramp and not later than 25% rise of
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the ramp. C
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Figure 2-4. Center Off Switch Adjustment Procedure
Figure 2-6. Fine Adjustment Procedure
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1. Directional Switch Adjustment Procedure (See Fig-
ure 2-5). J
a. Position is controlled by positioning of center off U
switch since cam is a combined assembly. S
b. Set switch to "make" (click is heard) just before
center off switch "makes." In no case shall it
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"make" before 50% cam rise. M
c. Further rotation shall cause the red switch actau-
tor to recede further into switch housing after
E
click is heard. N
d. Upon returning joystick to neutral, the switch
shall release (click is heard) not earlier that 75%
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rise of the ramp and not later than 25% rise of S
the ramp
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G 3.3 TROUBLESHOOTING PROCEDURES
c. If there is an in-line fuse, check to see if it is
blown.
1. The function will not operate when the handle is d. Check the controller on/off switch and the con-
moved. The LEDs do not light. nections. Voltage should be present at the (x)
terminal whent he controller is turned on.
a. Check that voltage is present at the positive (+) e. Check that the valve wiring is not shorted to
input terminal. ground. The LEDs will not light.
b. Check tha ground is connected to the negative
(–) terminal.
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3.6 1600242 CONTROLLER
3.4 1600235 CONTROLLER B
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O 3.8 1600257 CONTROLLER
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3.12 1600272 CONTROLLER 3.14 1600274 CONTROLLER O
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3.17 1600284 CONTROLLER O
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O 3.22 1600318 CONTROLLER 3.24 1600334 CONTROLLER
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TABLE OF CONTENTS
FIGURE DESCRIPTION PAGE
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FIGURE 4-1. CONTROLLER WITH SINGLE GATE & NO ROCKER SWITCH (CONTINUED)
C 35
36 to 49
7003950
Not Used
Plate, Retainer 1
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FIGURE 4-1. CONTROLLER WITH SINGLE GATE & NO ROCKER SWITCH (CONTINUED)
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FIGURE 4-2. CONTROLLER WITH SINGLE GATE & ROCKER SWITCH (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
7019101 1600257 Controllers
7019124 1600270/1600287 Controllers
7019191 1600273 Controllers
7019156 1600283/1600334 Controllers
7022824 1600318 Controllers
Potentiometer Options: 1
Use 7011925 1600235/1600257 Controllers (Was p/n
7003997)
7003970 1600239 Controllers
7003974 1600239/1600245/1600273 Controllers
S Not Available 1600231/1600270/1600283/1600287/
1600318 Controllers
E 8 Not Used
C 9 7019115 Stand-Off 2
T 10
7003963
Shaft & Sector Gear Options:
1600231/1600239/1600245 Controllers
1
FIGURE 4-2. CONTROLLER WITH SINGLE GATE & ROCKER SWITCH (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
18 7019110 Spacer, Head Gear 2
19 7019112 Washer/Bushing 1
20 7003946 Spring, Return & Bushing Kit 1
21 7019103 Pin 4
22 Not Serviced Rivet A/R
23 Bar, Mounting (Right Side) Options: 1
Not Required 1600231/1600235/1600257 Controllers
7019168 1600239/1600245/1600270/1600273/1600283/
1600287/1600318/1600334 Controllers
24 7003992 Washer 1
25 7003993 Nut 1 S
26 7003935 Gear, Slave 1
27 Screw Options: 2
E
7003969 1600231/1600235/1600239/1600245/1600257/ C
1600270/1600273/1600283/1600287/1600318
Controllers
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7003940 1600334 Controllers I
28
29
7003941 Washer
Microswitch Options:
2
A/R
O
7003961 1600231/1600235/1600245/1600257/1600270 2 N
Controllers
7003961 1600287/1600334 Controllers 1
Not Required 1600239/1600273/1600283/1600318 Controllers 0 4
30 Insulator Options: A/R
7019108 1600231/1600235/1600245/1600257/1600270
Controllers
1
R
7019138 1600287 Controllers 1 E
Not Required 1600239/1600273/1600283/1600318/1600334
Controllers
0
P
31 Insulator Options: A/R A
7019107 1600231/1600235/1600245/1600257/1600270
Controllers
1 I
Not Required 1600239/1600273/1600283/1600287/1600318/ 0 R
1600334 Controllers
32 Screw Options: A/R
7003998 1600231/1600235/1600245/1600257/1600270 2 P
Controllers A
7019106 1600287/1600334 Controllers 2
Not Required 1600239/1600273/1600283/1600318 Controllers 0 R
33 7003933 Gasket 1 T
34
7003988
Setscrew/Screw
1600231/1600235/1600239/1600245/1600270/
1
S
1600287 Controllers
Not Available 1600273/1600283/1600318/1600334 Controllers
35 Cam Assembly, Microswitch Options: A/R
Not Available 1600231/1600235/1600245/1600257 Controllers 1
7019125 1600270 Controllers 1
Not Required 1600239/1600273/1600283/1600318 Controllers 0
7019179 1600287/1600334 Controllers 1
FIGURE 4-2. CONTROLLER WITH SINGLE GATE & ROCKER SWITCH (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
36 Nut/Cam Assembly Options: A/R
7019113 1600231/1600235/1600239/1600245/1600257/ 1
1600270/1600287 Controllers
Not Required 1600273/1600283/1600318/1600334 Controllers 0
37 Heatsink Options: A/R
Not Required 1600231/1600235/1600239/1600245/1600257/ 0
1600273/1600283/1600318/1600334 Controllers
Not Available 1600270/1600287 Controllers 1
I 105
7003972
Boot, Switch Options:
1600231/1600235/1600239/1600245/1600257/
1
R 1600273/1600283/1600287/1600318/1600334
Controllers
7019127 1600270 Controllers
P 106 Handle Options: A/R
A 7003973 1600231/1600235/1600239/1600245/1600257/
1600273/1600283/1600287/1600318/1600334
2
R Controllers
FIGURE 4-2. CONTROLLER WITH SINGLE GATE & ROCKER SWITCH (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
108 Nut Options: 4
7003979 1600231/1600235/1600239/1600245/1600257/
1600270 Controllers
7019167 1600273/1600283/1600287/1600318/1600334
Controllers
109 7003980 Screw 4
110 Gasket Options: A/R
7003989 1600231/1600235/1600239/1600245/1600257/ 2
1600273/1600283/1600287/1600318/1600334
Controllers
Not Available 1600270 Controllers (Part of Item 106) 0
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FIGURE 4-3. CONTROLLER WITH ROUND GATE AND LIFT CAP (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
3 Screw Options: 4
Not Available 1600271 Controllers
7003952 1600230/1600242/1600274/1600278/1600284/
1600288/1600306 Controllers
7022816 1600317 Controllers
4 Plate, End 1
Not Available 1600271/1600278 Controllers (Not Shown)
4A Not Available 1600230/1600242 Controllers
4B 7019170 1600274/1600288/1600306/1600317 Controllers
5 Plate Options: A/R
S Not Required 1600230/1600242/1600271/1600278 Controllers 0
7019142 1600274 Controllers 2
E 7019171 1600284/1600288/1600306/1600317 Controllers 2
C 6 PC Board Assembly Options (See Items 101-109 for A/R
T Not Required
Breakdown):
1600230/1600242/1600271/1600274/1600278/ 0
I 1600306/1600317 Controllers
P 7019174 1600274/1600284/1600288/1600306/1600317
Controllers
A 9 7019111 Bearing, Gear 4
I 10
Not Required
E-Clip Options:
1600230/1600242/1600271 Controllers
A/R
R 7019145 1600274/1600278/1600284/1600288/1600306/
1600317 Controllers
11 Gear, Drive Options: A/R
P Not Required 1600271/1600278 Controllers 0
A 7003977 1600230/1600242/1600274/1600284/1600288/ 2
1600306/1600317 Controllers
R 12 Shaft Options: 2
T Not Available 1600230/1600242/1600271/1600278 Controllers
S 7019147
(Purchase Item 1G)
1600274/1600284/1600288/1600306/1600317
Controllers
FIGURE 4-3. CONTROLLER WITH ROUND GATE AND LIFT CAP (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
13 Cam Assembly Options: A/R
Not Available 1600230/1600242 Controllers (Not Shown) 2
7019193 Coupling, Cam (1600230/1600242 Controllers) 1
Not Available Spacer, Cam (1600230/1600242 Controllers) 1
Not Available Cam, 4 Hole (1600230/1600242 Controllers) 2
Not Available Cam (1600230/1600242 Controllers) 3
Not Available 1600278 Controllers 2
7019175 1600288/1600306 Controllers 2
Not Required 1600271/1600274/1600284/1600317 Controllers 0
14 Spacer, Cam A/R
Not Required 1600230/1600242/1600271/1600274/1600284/ 0 S
1600317 Controllers
7019176 1600278/1600288/1600306 Controllers 2
E
15 Shaft Options: A/R C
Not Available 1600230/1600242/1600278 Controllers (Purchase
Item 1G)
T
7019177 1600288/1600306 Controllers 2 I
Not Required 1600271/1600274/1600284/1600317 Controllers 0 O
16 Plate Options: A/R
Not Required 1600230/1600242/1600271 Controllers 0
N
7019142 1600288/1600306 Controllers 4
17
7019142 1600274/1600278/1600284/1600317 Controllers
Microswitch Options:
2
A/R
4
7003961 1600230/1600242/1600278/1600288/1600306 2
Controllers R
7003961 1600271 Controllers 4
Not Required 1600274/1600284/1600317 Controllers 0 E
18 Insulator Options: A/R P
7019138 1600230/1600242/16020278/1600288/1600306
Controllers
2
A
7019138 1600271 Controllers 4 I
19
Not Required 1600274/1600284/1600317 Controllers
Screw Options:
0
A/R
R
7019139 1600230/1600242/1600278/1600288/1600306 4
Controllers P
7019139 1600271 Controllers 8
Not Required 1600274/1600284/1600317 Controllers 0 A
20 Gear, Slave A/R R
7003976 1600230/1600242/1600274/1600284/1600288/
1600306/1600317 Controllers
1
T
Not Required 1600271/1600278 Controllers 0 S
FIGURE 4-3. CONTROLLER WITH ROUND GATE AND LIFT CAP (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
21 Potentiometer/Electrical Assembly Options: A/R
Not Available 1600230 Electrical Assembly Controllers 1
7003962 1600230 Controllers Potentiometer Only 2
(Includes Nut & Washer
Not Available 1600242/1600274/1600284 Electrical Assembly 1
Controllers
7003974 1600242/16002741600284 Controllers Potenti- 2
ometer Only
Not Available 1600271 Electrical Assembly Controllers (Pur- 1
chase Microswitches Item 17 Separately)
Not Available 1600278 Electrical Assembly Controllers 1
S Not Available 1600278 Controllers Potentiometer Only 2
E (Includes Nut & Washer
Not Available 1600278 Controllers Clamp Only 2
C Not Available 1600278 Controllers Potentiometer Adapter 2
T Only
I Not Available
7019178
1600288 Electrical Assembly Controllers
1600288/1600306 Controllers Potentiometer
1
2
O Only
P Not Required
7019149
1600271 Controllers
1600284/1600288/1600306/1600317 Controllers
0
2
A 25 Spacer Options: A/R
R Not Available 1600230/1600242 Controllers 2
Not Required 1600271 Controllers 0
T 7019144 1600274/1600278/1600284/1600288/1600306/ 2
S 1600317 Controllers
26 Screw Options: 2
7019143 1600230/1600242/1600274/1600278/1600284/ 1
1600288/1600306/1600317 Controllers
Not Required 1600271 Controllers 0
27 Use 7022813 Boot & Flange Kit (Includes Item 29) 1
Use 7022814 Boot (Was p/n 7003955)
FIGURE 4-3. CONTROLLER WITH ROUND GATE AND LIFT CAP (CONTINUED)
FIG & ITEM # PART NUMBER DESCRIPTION QTY. REV.
28 Spacer, Cam Options: A/R
Not Required 1600230/1600242/1600271/1600274/1600278/ 0
1600284 Controllers
7019174 1600288/1600317 Controllers 2
7019146 1600306 Controllers 2
29 Bezel/Plate, Plastic Options: 1
Use 7022813 1600230/1600242/1600271/1600274/1600284/
1600288/1600306 Controllers (Was p/n 7003954)
7022815 1600278/1600317 Controllers
30 7003956 Gasket 1
31 7003953 Washer 4 S
32 Screw Options: 4
7003952 1600230/1600242/1600271 Controllers E
7019137 1600274/1600284 Controllers C
7022817
7022811
1600278/1600317 Controllers
1600288/1600306 Controllers
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33 Not Used I
34 Gimble (Inner) Options: 1 O
7019122 1600242/1600278/1600288 Controllers
Not Available 1600230/1600271/1600274/1600306/1600317
N
Controllers
35 Gimble (Outer) Options: 1
7019123 1600242/1600278/1600288 Controllers
4
Not Available 1600230/1600271/1600274/1600306/1600317
36 Not Available
Controllers
Setscrew 2
R
E
PC BOARD ASSEMBLY (1600278 & 1600288
CONTROLLERS ONLY)
Ref. P
1600278 Controllers (Note: Was p/n 7019140 which Ref. A
is no longer available. Purchase individual circuit
cards.)
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7019172 PC BOARD ASSEMBLY (1600288 CONTROLLERS Ref. R
ONLY)
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1 7019181 Seal 1
2 7019182 Switch, Rotary 1
3 Not Serviced Plate 1
4 7019183 Screw, Flathead 2
5 7019184 Spacer 4
6 7019135 Washer 4
7 7019185 Screw 2
8 7019186 Screw 2
9 7019136 Screw 2
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10 7019187 Board, Circuit with Potentiometer 1 E
10A 4460265 Plug - 9 Position (Part of Console Box Harness) 1 C
4460268 Socket, Female (Part of Console Box Harness) 9
4460266 Receptacle - 9 Position (Part of p/n 7019187) 1 T
4460267 Pin, Male (Part of p/n 7019187) 9 I
11
12
7019163
Not Serviced
Coupling, Potentiometer
Heatsink
1
1
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JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. JLG Europe B.V.
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Polaris Avenue 63
D - 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI 2132 JH Hoofddorp
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+49 (0) 421 69 350 20 Hong Kong +39 029 359 5210 +31 (0) 235 655 665
+49 (0) 421 69 350 45 (852) 2639 5783 +39 029 359 5845 +31 (0) 235 572 493
(852) 2639 5797
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